D4.2-2 - Model For Effect of Ageing

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EASIE - Model for effect of ageing
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No .: D4.2/2
Model for effect of ageing
Publisher: Andreas Metzger, Saskia Käpplein, Thomas Misiek,

Karlsruher Institut für Technologie (KIT), Versuchsanstalt
für Stahl, Holz und Steine
Paavo Hassinen, Janne Mononen, Aalto University
School of Science and Technology (TKK)
Aneta Kurpiela, Jörg Lange, Technische Universität Dar-
mstadt (TUD)
Jessica Kochenbach, Institut für Sandwichtechnik - FH
Mainz (ISM)
Task: 4.2 and 4.3

Object: Durability of sandwich panels
This report includes 56 pages.
Date of issue: 15 November 2011
Versuchsanstalt für Stahl, Holz und Steine, Karlsruher Institut für Technologie (KIT) Tel.: +49 (0)721 608 42215
Abt. Stahl- und Leichtmetallbau, D-76128 Karlsruhe, Deutschland Fax: +49 (0)721 608 44078
This report may only be reproduced in an unabridged version. A publication in extracts needs our written approval.
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of report
No.: D4.2/2
Project co-funded under the European Commission Seventh Research and Technology De-
velopment Framework Programme (2007-2013)
Theme 4 NMP-Nanotechnologies, Materials and new Production Technologies
Prepared by
Andreas Metzger, Saskia Käpplein, Thomas Misiek, Karlsruher Institut für Technologie (KIT),
Versuchsanstalt für Stahl, Holz und Steine
Paavo Hassinen, Janne Mononen, Aalto University School of Science and Technology (TKK)
Aneta Kurpiela, Jörg Lange, Technische Universität Darmstadt (TUD)
Jessica Kochenbach, Institut für Sandwichtechnik - FH Mainz (ISM)
Drafting History
Draft Version 1.1 21 October 2011
Draft Version 1.2 11 November 2011
Draft Version 1.3
Draft Version 1.4
Final 15 November 2011
Dissemination Level
PU Public X
PP Restricted to the other programme participants (including the Commis-
sion Services)
RE Restricted to a group specified by the Consortium (including the Com-
mission Services)
CO Confidential, only for members of the Consortium (including the Com-
mission Services)
Verification and approval

Coordinator Approved by iSMainz, 17 November 2011
Industrial Project Leader
Management Committee
Industrial Committee
Deliverable
D4.2/2: Model for effect of ageing Due date:
Dez 2009
Completed:
Nov 2011
Versuchsanstalt für Stahl, Holz und Steine, Karlsruher Institut für Technologie (KIT)
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No.: D4.2/2
Table of contents
1 Preliminary remarks 4
2 Overview of specimens, tests and test arrangements 4
3 Assessment of the test results and conclusions concerning the durability 8
3.1 Introduction 8
3.2 PU-1 8
3.3 PU-2 13
3.4 EPS-1 18
3.5 EPS-2 18
3.6 RW-1 21
3.7 RW-2 24
3.8 RW-3 27
3.9 RW-4 31
4 Failure modes and developments during the ageing 34
4.1 Introduction 34
4.2 PU-1 34
4.3 PU-2 34
4.4 EPS-1 35
4.5 EPS-2 35
4.6 RW-1 35
4.7 RW-2 36
4.8 RW-3 36
4.9 RW-4 37
5 Determination of the shear modulus and strength from the full scale tests 46
6 Summary and conclusions 54
7 References 56
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1 Preliminary remarks
The Ensuring Advancement in Sandwich Construction through Innovation and Exploitation

(EASIE) Collaborative research project is divided in seven work packages. The Work Pack-
age 4 (WP 4) of the EASIE project deals with retrofitting, durability and maintenance of sand-
wich panels.
Within the scope of WP4, durability tests with artificially aged samples of different core materi-
als were performed by Aalto University School of Science and Technology (TKK), by Tech-
nische Universität Darmstadt (TUD) and by Institut für Sandwichtechnik - FH Mainz (ISM) (c.f.
test reports [1], [2] and [3]). Further, monitoring of an outdoor testing rig in Ingelheim, Germany
(which was started and initiated by Pfeiffer in 2002 [9]) for natural-ageing of several sandwich
panels of different core materials was continued within EASIE by ISM.
The aim of the durability test is to study the change of the mechanical properties of sandwich
panels when exposed to aging. The main goal of the Work Package 4 is, on the one hand, to
verify existing standards and predictions models and, on the other hand, to give new proposals
concerning the durability of sandwich panels and possibly the update of the existing European
product standard EN 14509 [7]. All tests were performed according to [7] and also based on
existing knowledge of recent projects, reports and publications.
The investigation involves direct methods by studying material parameters which are used
directly as design parameters as well as indirect methods by regarding material parameters
which actually are not directly included in the design process.
In the present report, a summary of the test results is given including a conclusion and as-
sessment concerning the time-dependent development of the strength and the failure modes.
A statistical evaluation as well as a comparison to already existing analytical ageing models, a
material-graded investigation of the development of the material parameters and possible pro-
posals for new design models will be given in Report D4.3.
Finally, a “Model to evaluate remaining service Life” is presented by TKK in Report D4.4.
The EASIE project has received financial support from the European Community’s Seventh
Framework Programme FP7/ NMP2-SE-2008 under grant agreement No 213302.
2 Overview of specimens, tests and test arrangements
Test specimens were delivered altogether by six manufacturers; two manufacturers of polyure-
thane foam cored specimen (PU-1 and PU-2), one manufacturer of polystyrene cored speci-
mens (EPS-1 with steel faces and EPS-2 with GRP faces) and three manufacturers of mineral
wool cored specimens (RW-1, RW-2, RW-3 and RW-4).
The European product standard [7] gives requirements to the durability of sandwich panels by
making classifications on the basis of the development of the tensile strength of artificially
aged small-scale specimens. Consequently, cross panel tensile tests with artificially aged
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No.: D4.2/2
small-scale samples were performed to investigate the behavior of the tensile strength. In the
same way, according to [8], compression tests, shear tests and wrinkling tests with artificially
aged small-scale samples were performed. The test arrangement for the different tests was
chosen according to [7] and [8] and is furthermore explicitly described in [1], [2] and [3]. The
specimens were exposed to aging in the climate chambers of TUD, ISM and TKK. Depending
on the core material of the sample, the ageing history according to DUR1 (75 °C, RH < 15 %)
or DUR2 (65°C, RH > 95 %) was followed. The ageing temperature for DUR 1 was chosen to
75 °C because the colour of the external faces of all test panels could be classified to be me-
dium light colour paintings.
Whereas small-scale samples for cross panel tensile tests, compression tests and shear tests
can be artificially aged without any problem in heating cambers, this is normally impossible
and unfeasible for the whole sandwich panel because of its large dimensions. For the investi-
gation of the durability of sandwich panels, the wrinkling stress, however, is an essential pa-
rameter of the design. This resulted in the fact that in previous research projects (for the first
time in 1988 at the Versuchsanstalt through Baehre [10]) a small-scale sample test for the
indirect determination of the wrinkling stress was developed and used. Whereas for the full-
scale bending test on the whole sandwich panel (e.g. in the vacuum chamber or in a 6-point
bending test) the compression stress in the upper face sheet is produced through a moment-
bending-loading of the whole panel, for the small-scale wrinkling tests the compression stress
in the face is directly induced by a normal force load in order to directly cause a wrinkling fail-
ure of the face sheet.
The advantage now consists in the fact that these small-scale samples can normally be aged
artificially because of their small dimensions and thus, a statement about the development of
the wrinkling stress is possible in function of the time to exposure.
Within EASIE, small scale wrinkling tests were performed by TKK and by ISM with specific test
arrangements. The small scale wrinkling tests at ISM were performed with bone-shaped sam-
ples to avoid failure at the support area. By comparison, the small scale wrinkling tests at TKK
were performed with rectangular samples whereas an additional load was applied to the mid-
dle line of the sample in order to cause an imperfection, and to simulate the reaction of the
loading beams of the full scale tests.
Within the scope of the EASIE project, for the first time also whole sandwich panels have been
aged artificially in the climate chambers of the project partner TUD and ISM in order to investi-
gate the development of the wrinkling stress of the full-scale sandwich panel as well as to get
a comparison with the wrinkling stress obtained from tests on small-scale samples and to veri-
fy the results.
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No.: D4.2/2
Performing full scale tests exposed to ageing was a special feature of EASIE. The testing re-
quires a big climate chamber while for the small-scale tests only a “small” climate cabinet is
sufficient. The climate chamber of TUD including some sample is shown in Fig. 2.1.
An overview of the performed tests including basic information about the several panel types
and an anonymous assignment to the manufacturers is given in Tab. 2.1
Fig. 2.1: Climate Chamber for the full scale panels (Photo by Aneta Kurpiela, TUD)
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No.: D4.2/2
measured mean
Sample overview Test overview
thickness [mm]
Cross Panel Tensile Test
Material Test Face Layer

Wrinkling full scale test
outer face (steel core)
inner face (steel core)
Small wrinkling test
Compression Test
Ageging History
Density of Core
complete panel
3)
Manufacturer
Shear test
Notation
Material
1)
119,4 0,54 0,55 TUD ISM TUD TUD TUD TUD ./.
PUR PU-1 Manufacturer 1 DUR1
2)
119,2 0,545 0,562 ./. TKK ./. TKK ./. TKK TKK
1)
100,5 0,42 0,41 TUD ISM TUD TUD TUD TUD ./.
PIR PU-2 Manufacturer 2 DUR1
2)
99,4 0,427 0,425 ./. TKK - TKK ./. TKK TKK
EPS TUD 1)
EPS-1 120,3 0,53 0,53 ISM TUD TUD TUD TUD ./.
(steel faces) +ISM
Manufacturer 3 DUR1
EPS 1)
EPS-2 121,3 2,0 2,0 ./. ISM TUD TUD TUD TUD ./.
(GRP faces)
2)
117,9 0,473 0,478 ./. TKK TKK TKK TKK TKK TKK
RW-1 Manufacturer 4
1)
118,3 0,47 0,46 ISM ISM ./. ISM ./. ./. ISM
2)
119,7 0,472 0,477 - TKK TKK TKK TKK TKK TKK
4)
RW-2 Manufacturer 5
4) 4) 1)
119,48 ./. ./. ./. ISM ./. ./. ./. ./. ./.
mineral wool DUR2
2)
RW-3 Manufacturer 6
1)
120,10 0,60 0,51 ISM ISM ./. ISM ./. ./. ./.
2)
RW-4 Manufacturer 5
1)
119,29 0,45 0,45 ISM ISM ./. ISM ./. ./. ./.
Tests performed by:

TUD = Technische Universität Darmstadt
ISM = Institut für Sandwichtechnik – FH Mainz
TKK = Aalto University School of Science and Technology
1)
bone-shaped sample
2)
rectangular sample
3)
For data privacy, the manufacturers are made anonymous.
4)
RW-2 test series was not completely performed because it was replaced by RW-4 during the project.
Tab. 2.1: Overview of specimens and performed tests
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3 Assessment of the test results and conclusions concerning the durability
3.1 Introduction
For each test performed within the scope of the investigations, detailed test results can be
taken from [1], [2] and [3] as well as the corresponding test curve which normally depicts the
behavior of the specimens by a load-displacement-diagram or stress-strain diagram.
In this chapter, the test results determined during the tests performed by the project partici-
pants TUD, ISM and TKK are summarized, assessed and evaluated with regard to durability.
A description and discussion of the test results was already performed in [1], [2] and [3], and is
cited below and supplemented or edited when needed.
In the following chapters, the progress of the mean values of single material parameters in the
course of the artificial ageing is presented for each specimen type. The results are presented
in one or two diagrams depending on the number of project partners involved in the test pro-
cedure for one specimen type.
In the diagrams relative values of the strength and modules have been presented, i.e. the de-
velopment over time was related to the initial value of the specimens.
Data points mark the respective mean value of the appropriate material parameter for different
ageing steps. The successive data points are connected linearly to each other.
In addition, the letters in the data points mark the test type (T= Cross panel tensile test, C=
Compression test, S= Shear Test, W= Wrinkling test). In the diagrams the curves of the mod-
ulus values are shown dashed, whereas the curves of strengths are visualized using a solid
line. The mean values of the wrinkling stress can be read at the data points of the dash-dotted
lines. Through the form of the data point it is distinguished whether the wrinkling stress was
determined from the full-scale test, from the small scale test with bone-shaped samples or
from the small-scale test with rectangular samples.
Furthermore, the test results of the different material parameters and their curves can be clear-
ly distinguished through the coloring. In the subsequent chapters, a description of the age-
dependent process of the material parameters is given for each specimen type.
In the subsequent assessment, only those tests were taken into account which have a clear
corresponding failure. In the following considerations, any considered value is the mean value,
also when it is not explicitly noticed.
3.2 PU-1
The full scale tests which are shown with a magenta dash-dotted curve in Fig. 3.1 were done
after twelve and after 24 weeks ageing. The test results show a continuous increase of the
values with the ageing, in doing so the ultimate wrinkling stress after 24 weeks represents 108
% of the initial value.
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No.: D4.2/2
The relative ultimate stresses compared to the initial strengths of the small-scale wrinkling test
with bone-shaped samples have a noticeable difference after the exposure to ageing of two,
six and twelve weeks. The test results after a longer ageing period (24 weeks) are comparable
with the initial test results (c.f. Fig. 3.1, red dash-dotted). Nevertheless, the lowest value (ap-
prox. 82 % of the initial value) during the ageing history has to be taken into account for further
considerations. By comparison, the relative ultimate wrinkling stress in the small-scale wrin-
kling test with rectangular samples even increases after two weeks to 117 % of the initial val-
ue, but finally decreases to 97 % after 12 weeks (c.f. Fig. 3.2, brown dash-dotted).
Although we can recognize, that in all three types of wrinkling tests the relative ultimate wrin-
kling stresses compared to the initial strengths after the end of our chosen artificial ageing
period are close to the initial values, we have to notice the lower values during ageing history.
The results of the tests with small specimens (tension, compression and shear tests) show
that the mechanical values have different behavior depending on the kind of test.
The shear strength (green massive curve) and the compression strength (blue massive curve)
stay on the same initial level or are higher during the ageing and after the complete period of
ageing.
Maybe the strong rise of the compression strength is due to the fact, that the compression
strength is no ultimate value but a fixed value at a specific strain (as known 10 %).
The shear modulus (green dashed curve) decreases directly after two weeks to 84 % of the
initial value and afterwards stays on an almost constant level of 86 to 88 %. The compression
modulus decreases down to 82 % of the initial value after two weeks. Then, it increases,
reaching the level of 106 % of the initial value at the end of ageing time of twelve weeks.
The tensile strength (yellow massive curve) decreases during the ageing while in contrast the
tensile modulus (yellow dashed curve) increases. This behavior appears for the tensile tests
performed by TUD (see Fig. 3.1) as well as for the tensile tests performed by TKK (see Fig.
3.2). Because the tensile tests have been performed by TKK and TUD, it makes also sense to
compare the absolute values of the tensile strength and the tensile modulus as it is done in
Fig. 3.3. The different colors show the assignment to the test performer while the massive
lines still show the strength and the dashed lines still show the modulus. Although the behavior
of the relative tensile parameters during the ageing in the tests performed by TKK and TUD is
similar, there are differences in the absolute values. This is maybe due to the difference in
preparing the specimens and the test equipment in the two laboratories. After an aging period
of twelve weeks, the values of the tensile strength and modulus are however, close to each
other.
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No.: D4.2/2
PU-1
DUR 1 (75°C, RH<15 %)
(Tests performed at TUD and ISM)
1,8
1,6
1,4
Relative strength and relative modulus [ - ]
1,2
0,8
0,6
0,4
0,2
0
0 2 4 6 8 10 12 14 16 18 20 22 24
Time of exposure [weeks]
Wrinkling stress (full scale)
Wrinkling stress (small scale, bone-shaped sample)
Shear strength
Shear modulus
Cross-panel tensile strenght
Elasticity modulus in tensile test
Cross-panel compressive strength
Elasticity modulus in compressive test
Fig. 3.1: Relative development of the strength and modulus of PU-1 specimens (Part 1)
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No.: D4.2/2
PU-1
DUR 1 (75°C, RH<15 %)
(Tests performed at TKK)
1,6
1,4
1,2
0,8
0,6
0,4
0,2
0
0 2 4 6 8 10 12 14 16 18 20 22 24
Wrinkling stress (small scale, rectangular sample)
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No.: D4.2/2
PU-1: Comparison of the Results of the

Cross Panel Tensile Tests
DUR 1 (75°C, RH<15 %)
(Tests performed at TUD and TKK)
5 0,3
4,5
0,25
3,5
3
Modulus [N/mm2]
Strenght [N/mm2]
2,5 0,2
1,5
0,15
0,5
0 0,1
0 2 4 6 8 10 12 14 16 18 20 22 24
Elasticity modulus in tensile test (Tests perfomed at TUD)

Elasticity modulus in tensile test (Tests perfomed at TKK)
Cross panel tensile strength (Tests perfomed at TUD)
Cross-panel tensile strength (Tests perfomed at TKK)
Fig. 3.3: Comparison of the absolute tensile strength and modulus of PU-1 specimens
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No.: D4.2/2
3.3 PU-2
The full scale tests (magenta dash-dotted curve in Fig. 3.4) were done after a exposure to ag-
ing for twelve and 24 weeks. The test results show a very strong decrease of the wrinkling
stress to 42 % of the initial value after 12 weeks ageing. Unfortunately, all 24-weeks aged
specimens failed by a shear failure. Consequently, a wrinkling stress can only be calculated as
a minimum value and the corresponding value stays on the same level as 12 weeks aged
samples.
The ultimate stresses compared to the initial strength of the small-scale wrinkling test with
bone-shaped samples have a noticeable decrease of 78 % after two weeks and 77% after six
weeks of ageing. After the exposure to ageing of twelve weeks the values increase up to
105 % of the initial value. The mean value of wrinkling stress after the complete period of age-
ing (24 weeks) is 90 % and therefore comparable to the result of initial tests (c.f. Fig. 3.4, red
dash-dotted). Although the final value after the ageing is comparable to the results of the initial
tests, the low values after two and six weeks are in use for further considerations. Because of
premature detach of the face-layer a part of the specimens was not considered in the evalua-
tion (see [2], annex 2, page 1, 2nd table).
By comparison, the relative ultimate wrinkling stress in the small-scale wrinkling test with rec-
tangular samples even increases after two weeks to 151 % of the initial value and even to
164 % after six weeks. The final value after 12 weeks ageing is 143 % (c.f. Fig. 3.5, brown
dash-dotted). Maybe to understand that strong increase, we have to take into account that the
initial values of the wrinkling stress have a large scatter including one very small single wrin-
kling stress value which was taken into account.
Results based on small-scale specimens show that the mean compression strength (blue
massive curve), the mean tension modulus (yellow dashed curve), the mean compression
modulus (blue dashed curve) with exception of the 1-week mean value and the shear modulus
(green dashed curve) increase during the ageing. The shear strength also tends to stay on the
initial level, the lowest mean value being 84 % of the initial value after an aging of 24 weeks.
The changes of the parameters are shown in Fig. 3.4.
A clear decrease of the tensile strength (yellow massive curve) was observed. The lowest ten-
sile strength values decrease to 49 % in the tests of TUD and also to 49 % in the tests of TKK.
An increasing tensile modulus on the one hand, as well as a decreasing tensile strength on the
other hand, was also observed for the PU-1 samples.
This behavior appears for the tensile tests performed by TUD (see Fig. 3.4) as well as for the
tensile tests performed by TKK (see Fig. 3.5). Because of having tensile tests performed by
TKK and TUD, it makes also sense to compare the absolute values of the tensile strength and
the tensile modulus as it is done in Fig. 3.6. Here, the absolute tensile strength values are
close to each other with sole exception of the 6-weeks values. The tensile modulus at the be-
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No.: D4.2/2
ginning of the ageing history is close each other, while it tends to different values during the
ageing.
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No.: D4.2/2
PU-2
DUR 1 (75°C, RH<15 %)
1,6
1,4
1,2
0,8
0,6
0,4
0,2
0
0 2 4 6 8 10 12 14 16 18 20 22 24
Wrinkling stress (full scale) [wrinkling stress for 24 weeks ageing is not avaible due to shear failure]
Wrinkling stress (full scale) [wrinkling stress as minimum value due to shear failure]
Shear strength
Shear modulus
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PU-2
DUR 1 (75°C, RH<15 %)
(Tests performed at TKK)
2,5
2
1,5
0,5
0
0 2 4 6 8 10 12 14 16 18 20 22 24
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PU-2: Comparison of the Results

of the Cross Panel Tensile Tests
DUR 1 (75°C, RH<15 %)
(Tests performed at TUD and TKK)
9
8 0,27
0,22
6
Modulus [N/mm2]
Strenght [N/mm2]
5
0,17
0,12
3
2
0,07
0 0,02
0 2 4 6 8 10 12 14 16 18 20 22 24
Elasticity modulus in tensile test (Tests perfomed at TUD)

Cross panel tensile strength (Tests perfomed at TUD)
Fig. 3.6: Comparison of the absolute tensile strength and modulus of PU-2 specimens
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No.: D4.2/2
3.4 EPS-1
The EPS-1 specimens are made of steel sheet faced sandwich panels. The results of the
wrinkling tests (full scale tests and small scale tests with bone-shaped samples) show no no-
ticeable difference between the ultimate stresses after the ageing and the initial values. The
wrinkling stress in the full scale test lies close to the initial value, reaching the minimum value
of 94 % after 1 week of ageing (see magenta dash-dotted curve in Fig. 3.7). However, we
have to notice, that four initial full scale wrinkling tests have been performed, while only one
test has been performed for each ageing time. In the small-scale tests with bone-shaped sam-
ples (see red dash-dotted curve in Fig. 3.7) a clear increase of the wrinkling stress after one
week ageing was observed, afterwards the wrinkling stress falls slightly below the initial value,
resulting in 88 % of the initial value after an aging of 12 weeks.
The tests on the core material (see corresponding curves in Fig. 3.7) show that the values of
strength and modulus in the compression and shear test either stay on the same level or are
higher after ageing in comparison with the initials test results. However a clear decrease of the
tensile strength and tensile modulus was observed. The minimum values are reached after 12
weeks of ageing, resulting in 68 % for the tensile strength (yellow solid curve in Fig. 3.7) and
79 % for the tensile modulus (yellow dashed curve in Fig. 3.7) compared to the initial values.
3.5 EPS-2
The EPS-2 specimens are made of sandwich panels with glass-fibre reinforced laminate fac-
es. The ultimate stresses in the small-scale wrinkling test with bone-shaped samples during
the complete period of the ageing show no noticeable difference compared to the initial
strengths, except a decrease of the wrinkling strength to a minimum value of 81 % of the initial
value after 1 week (see red dash-dotted curve in Fig. 3.8). Full-scale wrinkling tests with EPS-
2 panels have not been performed.
The tests on the core material (see corresponding curves in Fig. 3.8) show that the values of
strength and modulus in the compression and shear test are higher after ageing in comparison
with the initial test results. However, a clear decrease of the tensile strength and tensile
modulus was observed. The tensile modulus (yellow dashed curve in Fig. 3.8) decreases, re-
sulting in a minimum value of 88 % after 12 weeks ageing. The tensile strength (yellow solid
curve in Fig. 3.8) increases to 110 % after 1 week, then decreases to 64 % after 6 weeks, and
finally once again increase to 98 % after 12 weeks of ageing.
When comparing EPS-1 test results with EPS-2 test results, we can find similar behavior of the
material parameters, with the exception of the contrary behavior of the wrinkling stress after an
aging of one week and the difference of the tensile strength after an aging of twelve weeks.
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No.: D4.2/2
EPS-1
DUR 1 (75°C, RH<15 %)
1,4
1,2
1
0,8
0,6
0,4
0,2
0
0 2 4 6 8 10 12
Shear strength
Shear modulus
Fig. 3.7: Relative development of the strength and modulus of EPS-1 specimens
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No.: D4.2/2
EPS-2
DUR 1 (75°C, RH<15 %)
1,6
1,4
1,2
0,8
0,6
0,4
0,2
0
0 2 4 6 8 10 12

Shear strength
Shear modulus
Fig. 3.8: Relative development of the strength and modulus of EPS-2 specimens
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3.6 RW-1
The relative ultimate stresses scaled to the initial strength of the different tests of the RW-1
specimens had noticeable differences after the exposure to ageing.
The ultimate wrinkling stress of the small-scale rectangular specimens after the 8 weeks age-
ing period exceeded the strength of 80 % compared to the initial strength. However, it is to be
noticed the drop-off of the wrinkling stress down to 63 % after the aging of two weeks (c.f.
brown dash-dotted curve in Fig. 3.9). While the wrinkling stress in the small-scale test with
bone-shaped samples (c.f. red dash-dotted curve in Fig. 3.9) after two weeks of artificial aging
was 75 % of the initial stress, after the 4 weeks ageing period it even increased to 107 %
compared to the initial strength.
During the full-scale tests performed at ISM (with a span of 3000 mm as well as with a span of
4000 mm), a wrinkling failure occurred only in one test. Thus, a calculation of the wrinkling
stress for a longer period is not expedient. In one full-scale test the specimen failed by a shear
failure. In all other tests the reason of the failure was a detachment of the lower face (face
sheet subjected to tension) from the core.
This special kind of failure mode must presumably be caused by a small tensile strength of the
bond between core and face. The tensile strengths of almost all performed tensile tests do not
fulfill the requirements of EN 14509 with 0,018 N/mm², whereby the failure occurred in the in-
terface area between the mineral wool and the face sheet.
Consequently, the performance of tensile tests at the ISM was stopped after 6 tests due to low
results. The tensile tests at TKK were performed for all ageing times from the beginning to the
end confirming the low values for the tensile strength as well as the failure mode. The ultimate
cross-panel tensile stress (yellow massive line in Fig. 3.9) was only 26 % and the tensile mod-
ulus (yellow dashed line in Fig. 3.9) was only 32 % after the ageing of eight weeks compared
to the initial strength in the tests performed by TKK.
Since the tensile tests at ISM were stopped due to low tensile strengths after ageing of the
specimens within one week, a comparison of the absolute value of the tensile strength and the
tensile modulus resulting from the tests performed at TKK is not possible. In Fig. 3.10, howev-
er, the absolute values are presented for the sake of completeness and clarification of the very
low values.
Furthermore, the shear and tension tests performed at TKK provided also very low strengths
and modules resulting in values in the range of 40 % to 60 % of the initial value (see corres-
ponding curves in Fig. 3.9)
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No.: D4.2/2
RW-1
DUR 2 (65°C, RH>95 %)
(Tests performed at ISM and TKK)
1,2
1
0,8
0,6
0,4
0,2
0
0 2 4 6 8
Wrinkling stress (full scale) [is not available because of no wrinkling failure during tests]
Shear strength
Shear modulus
Fig. 3.9: Relative development of the strength and modulus of RW-1 specimens
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No.: D4.2/2
RW-1: Comparison of the Results of the

DUR 2 (65°C, RH>95 %)
(Tests performed at ISM and TKK )
6 0,1
0,09
5
0,08
0,07
4
0,06
Modulus [N/mm2]
Strenght [N/mm2]
3 0,05
0,04
2
0,03
0,02
1
0,01
0 0
0 2 4 6 8
Elasticity modulus in tensile test (Tests perfomed at ISM) [Evaluation not possible]
Cross panel tensile strength (Tests perfomed at ISM) [Testing was stopped after 6 tests because of low results]
Fig. 3.10: Comparison of the absolute tensile strength and modulus of RW-1 specimens
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No.: D4.2/2
3.7 RW-2
The tests with RW-2 specimens were stopped prematurely due to very low results and re-
placed with a series of RW-4 specimens produced by the same manufacturer. Due to the re-
placement of the RW-2 test series by RW-4, only the initial wrinkling tests with bone-shaped
samples have been performed by ISM.
Despite of the replacement of the RW-2 samples, the tests series with RW-2 specimens was
finished by TKK and the test results of the different tests in terms of the relative mean values
of the strength and respectively the modulus can be seen in Fig. 3.11
The largest reductions were measured in the cross-panel tensile strength (yellow massive line
in Fig. 3.11). Cross-panel compression strength (blue massive line in Fig. 3.11), shear strength
(green massive line in Fig. 3.11) and wrinkling stress determined from small-scale rectangular
samples (brown dash-dotted line in Fig. 3.11) decrease also due to the ageing but the relative
reduction is smaller than that of the relative tensile strength. In the analysis of the shear
strength, only the results caused by a shear failure have been taken into account. For in-
stance, after an ageing period of two weeks, no shear failures were observed, but the speci-
mens failed through a core compression failure or a wrinkling failure of the face.
Comparison of the modulus of elasticity and shear modulus show that the cross-panel tensile
modulus (yellow dashed line in Fig. 3.11) reduces continuously with the time of exposure to
ageing. Changes in the cross-panel compressive modulus (blue dashed line in Fig. 3.11) are
small except the modulus after the ageing of eight weeks, which ageing time causes a large
reduction in the modulus down to 30 %. The light changes in the value of the shear modulus
(green dashed line in Fig. 3.11) can be observed after the ageing of four and eight weeks.
In Fig. 3.12 the absolute values for the tensile strength and for the tensile modulus are pre-
sented.
It has to be noted, that the most failures of the RW-2 specimens exposed to DUR2 ageing
history were caused by the corrosion of the steel sheet faces, not by the ageing of the bond or
the core. Thus, the physical background of the failures is different compared to failures of the
other test specimens.
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No.: D4.2/2
RW-2
DUR 2 (65°C, RH>95 %)
1,4
1,2
1
0,8
0,6
0,4
0,2
0
0 2 4 6 8
Wrinkling stress (full scale) [no test series performed]
Wrinkling stress (small scale, bone-shaped sample) [no complete test series performed]
Shear strength
Shear modulus
Cross-panel tensile strength
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No.: D4.2/2

DUR 2 (65°C, RH>95 %)
16 0,2
0,18
14
0,16
12
0,14
10
0,12
Modulus [N/mm2]
Strenght [N/mm2]
8 0,1
0,08
6
0,06
0,04
2
0,02
0 0
0 2 4 6 8
Elasticity modulus in tensile test (Tests perfomed at ISM) [no test series performed]
Cross panel tensile strength (Tests perfomed at ISM) [no test series performed]
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No.: D4.2/2
3.8 RW-3
Large changes in the wrinkling stress determined from the bone-shaped specimens were
measured in the test series. Similar to RW-1 specimens, the wrinkling stress (red dash-dotted
line in Fig. 3.13) even increases after an ageing-time of four weeks, resulting in 140 % of the
initial value.
Altogether nine full-scale tests with RW-3 cored specimens were performed at ISM. Three
specimens were loaded in initial tests, two of which failed by wrinkling failure mode and one by
a core compression failure because of narrow support width. Three specimens were loaded
after the exposure to aging of one week. Only one specimen failed by wrinkling failure. The
other two specimens failed by a shear failure and a delamination failure. The remaining three
specimens were loaded after the exposure to aging for four weeks. Two of the specimens
failed by a delamination failure; one specimen failed by a core compression failure at support.
The development of the wrinkling stress can be followed directly only up to the aging of one
week, which shows a light reduction of the strength. The results based on the shear failure,
delamination failure and core compression failure show a lower bound result to the wrinkling
stress.
The further tests performed at TKK show, that the relative ultimate stresses scaled to the initial
strength of the different tests of the RW-3 specimens show the change of the cross-panel ten-
sile strength (yellow massive curve) to be the largest and the change of the wrinkling strength
of the rectangular samples (brown dash-dotted curve) the most small of the four strength val-
ues (c.f. Fig. 3.13). The changes in the strengths take place during the first two weeks, after
which time relative small changes can be observed in the test results in average.
Because of the local buckling failures of the initial shear test specimens, the development of
the shear strength (green massive curve) does not describe the real changes of the shear
strength of the core, because the initial shear strength could not be measured. However, the
relative shear strength value calculated on the basis of the highest load is a lower bound limit
to the initial shear strength of the core. The real failure modes of the shear test specimens
shall be taken into account in the further analysis of the test results. The changes in the shear
modulus (green dashed curve in Fig. 3.13) are very light.
Comparison of the mean values of the modulus of elasticity of the core layer shows the
changes to be the largest in the tensile modulus (yellow dashed curve in Fig. 3.13). The
changes take place mainly during the first two weeks of the ageing. Variation of the compres-
sion modulus (blue dashed curve in Fig. 3.13) is resulted partly in the difficulty in the determi-
nation of a linear part in the curved stress-strain line. The large decrease of the compression
modulus between the four and eight weeks is partially caused by large variation of the shapes
of the stress-strain curves after the exposure to ageing of eight weeks (c.f. [1], Annex 5, page
5).
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No.: D4.2/2
Once again, in Fig. 3.14 the absolute values of the results of the tensile tests performed by
ISM and by TKK are compared.
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No.: D4.2/2
RW-3
DUR 2 (65°C, RH>95 %)
1,6
1,4
1,2
0,8
0,6
0,4
0,2
0
0 2 4 6 8
Wrinkling stress (full scale) [wrinkling stress for 4 weeks ageing is not avaible due to no wrinkling failure]
Wrinkling stress (full scale) [wrinkling stress as minimum value due to no wrinkling failure]
Shear strength
Shear modulus
Cross-panel tensile strength
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No.: D4.2/2

DUR 2 (65°C, RH>95 %)
20,00 0,2
18,00 0,18
16,00 0,16
14,00 0,14
12,00 0,12
Modulus [N/mm2]
Strenght [N/mm2]
10,00 0,1
8,00 0,08
6,00 0,06
4,00 0,04
2,00 0,02
0,00 0
0 2 4 6 8
Elasticity modulus in tensile test (Tests perfomed at ISM)

Cross panel tensile strength (Tests perfomed at ISM)
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No.: D4.2/2
3.9 RW-4
In the wrinkling tests with bone-shaped specimens, there is a decrease of the wrinkling
strength after 1 week ageing to 69 % of the initial value. After a longer exposure to aging the
wrinkling strength increases, reaching 98 % of the initial stress after 4-weeks aging.
Similar to the RW-3 panels, the full-scale tests show in addition to a wrinkling failure also other
failure modes, namely a shear failure or a delamination failure of the face. In the initial tests,
two specimens failed through a wrinkling failure, while for the 1-week and 4-week aged panels
only one specimen in each case failed by wrinkling. Consequently, we can calculate a wrin-
kling stress for the complete ageing period and present the changes which are only small as
can be seen in the magenta dash-dotted curve in Fig. 3.15.
The further tests performed at TKK show, that the relative ultimate stresses scaled to the initial
strength of the different tests of the RW-4 specimens show the change of the cross-panel ten-
sile strength (yellow massive curve) to be the largest and the change of the wrinkling stress of
the rectangular samples (brown dash-dotted curve) the most small of the four strength values
(c.f. Fig. 3.15). The changes in the strengths take place during the first week with a similar
rate. The reduction of the cross panel tensile strength continues up to the ageing period of four
weeks. The rate of the reduction of the cross-panel compression strength (blue massive curve)
and the shear strength (green massive curve) decreases after the ageing period of one week.
Relative changes in the wrinkling strength are small, despite of the change of the failure mode.
However, the wrinkling stress reduces about 16% during the time of ageing of eight weeks.
Because of the local buckling and the core compression failures of the initial shear test speci-
mens, the described development of the shear strength does not represent the real changes of
the shear strength of the core and bond, because the initial shear strength could not be meas-
ured. However, the relative shear strength value calculated on the basis of the highest load is
a lower bound limit to the initial shear strength of the core. The real failure modes of the shear
test specimens shall be taken into account in the further analysis of the test results.
Comparison of the mean values of the modulus of elasticity of the core layer and the shear
modulus shows similar developments of all three values of modulus (c.f. Fig. 3.15). The
changes take place mainly during the first week of the ageing. The shear modulus (green
dashed curve) and the compression modulus (blue dashed curve) decreases down to the
range of 80 % till 90 %, while the tensile modulus falls slightly below 80 % for the 4-weeks and
8-weeks aged samples.
The absolute values of the tensile strength and modulus measured in the laboratories of ISM
and TKK are compared in Fig. 3.16.
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No.: D4.2/2
RW-4
DUR 2 (65°C, RH>95 %)
(Tests performed at TKK and ISM)
1,1
0,9
0,8
0,7
0,6
0,5
0,4
0 2 4 6 8
Shear strength [lower limit: ultimate shear stress is determined partially by a buckling or a compression failure]
Shear modulus
Fig. 3.15: Relative development of strength and modulus of RW-4 specimens
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No.: D4.2/2

DUR 2 (65°C, RH>95 %)
(Tests performed at ISM or TKK)
16,00 0,1
0,09
14,00
0,08
12,00
0,07
10,00
0,06
Modulus [N/mm2]
Strenght [N/mm2]
8,00 0,05
0,04
6,00
0,03
4,00
0,02
2,00
0,01
0,00 0
0 2 4 6 8
Elasticity modulus in tensile test (Tests perfomed at ISM)

Cross panel tensile strength (Tests perfomed at ISM)
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No.: D4.2/2
4 Failure modes and developments during the ageing
4.1 Introduction
The failure modes of the different panel types in the several tests are described in detail in the
corresponding test reports [1], [2] and [3]. Thus, in the present report, the descriptions are
quoted subsequently sometimes supplemented by additional information or abridged. For each
type of specimen, representative pictures of the failure modes (taken from [1], [2] and [3]) are
given at the end of this chapter.
4.2 PU-1
No changes in the failure modes of wrinkling, shear, compressive and tensile test specimens
were observed due to the exposure to the ageing in DUR 1 conditions. Wrinkling failure took
place at the compressed face sheet in the full scale tests close to the load introduction line (c.f.
Fig. 4.1 (a)). In the small scale tests with bone-shaped specimens a wrinkling failure of the
compressed faces took place as well. The wrinkling failure in the in the small-scale tests with
rectangular specimens took place because of a detachment of the face and core outside the
area of the transversal loading beam. The failure modes are shown in Fig. 4.1 (b). The failure
in the shear tests took place in the core layer between the load introduction point and the sup-
port (see Fig. 4.1 (c)). The failure in the cross-panel tension test took place in the core layer
close to the bonding and is shown in Fig. 4.1 (d).
4.3 PU-2
During the full scale test either a wrinkling or a shear failure mode was observed. In the small
scale test with bone-shaped specimens delamination on the compressed face took place. Ad-
ditionally a large dispersion of the results in both wrinkling tests (small-scale with bone-shaped
samples and full scale tests) was observed. The ageing in DUR1-test is not the sole reason for
the different failure modes and the relatively high dispersion of the results. The weak bonding,
which was noted directly after the production of the specimens, has influences in the men-
tioned test results. The failure modes of full scale wrinkling tests are shown in Fig. 4.2 (a).
Wrinkling failure in the in the small-scale tests with rectangular samples took place because of
a detachment of the face and core outside the area of the transversal loading beam The failure
modes of small scale wrinkling tests are shown in Fig. 4.2 (b). The failure in the shear test took
place in the core layer between the load introduction point and the support (see Fig. 4.2 (c)).
The failure in the cross-panel tension tests took place either in the core layer close to the
bonding or in the bonding between the core and the cover sheet and is shown in Fig. 4.2 (d).
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No.: D4.2/2
4.4 EPS-1
No changes in the failure modes of the wrinkling, shear, compressive and tensile test speci-
mens were observed due to the exposure to the ageing in DUR1 conditions. Wrinkling failure
took place at the compressed face sheet in the full scale tests close the load introduction line.
The failure mode is shown in Fig. 4.3 (a). The failure mode of the small scale wrinkling tests
was a clear wrinkling of the compressed face and is shown in Fig. 4.3 (b). The failure in the
shear tests took place in the core layer between the load introduction point and the support.
The failure modes are shown in Fig. 4.3 (c). The failure in the cross-panel tension tests took
place in the core layer close to the bonding and partially in the bonding as well and is shown in
Fig. 4.3 (d).
4.5 EPS-2
No changes in the failure modes of wrinkling, shear, compressive and tensile test specimens
were observed due to the exposure to the ageing in DUR1 conditions. Wrinkling failure took
place at the compressed face sheet in the small scale test with bone-shaped specimens. The
failure mode is shown in Fig. 4.4 (a).
The failure in the shear test (c.f. Fig. 4.4 (b)) took place in the core layer between the load in-
troduction point and the support. The failure in the cross-panel tension test took place in the
core layer close to the bonding and is shown in Figure 29.
4.6 RW-1
No changes in the failure modes of any test specimens were observed due to the ageing.
The wrinkling failure in the small-scale tests with rectangular samples took place because of
the detachment of the face and core outside the area of the transversal loading beam (see Fig.
4.5 (a), top). The bone-shaped samples also failed by wrinkling and the typical failure mode is
shown in Fig. 4.5 (a), bottom. The failure mode of the full-scale panels in almost every case
was the detachment of the lower face (c.f. Fig. 4.5 (e)).
The failure in the tension test took place at the core layer close to the bonding as shown in Fig.
4.5 (b). The failure in the compression test took place in the core layer. There were clear varia-
tions in the compression failure modes. The core layer yielded either only inside a very thin
layer or evenly across the entire depth of the specimen. One failure mode of the compression
test is shown in Fig. 4.5 (c). The failure in the shear test took place in the core layer vertically
under the loading point and extended horizontally close to the bonding layer to the end of the
specimen. The failure mode of the shear test is shown in Fig. 4.5 (d).
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No.: D4.2/2
4.7 RW-2
The initial wrinkling failure in the small-scale wrinkling tests with rectangular samples followed
the line of the transversal loading beam or was caused by a detachment of the face and core
outside the area of the transversal loading beam (Fig. 4.6 (a) left). The failure mode changed
due to the DUR2 ageing periods because of the corrosion between the zinc coating and steel
in the internal surface of the external face. Due to a low strength between the face and core,
the failure modes were caused by detachment of the face and core (c.f. Fig. 4.6 (a) right).
The failure mode of the small-scale wrinkling tests with bone-shaped samples was a wrinkling
failure, but only the initial tests were performed, because the RW-2 test series was replaced by
the RW-4 samples of the same manufacturer.
The failure mode of the cross-panel tensile test specimens took place close to the external or
internal face (Fig. 4.6 (b) left). The failure mode remained similar, however, the tensile strength
decreased during the ageing periods because of the internal corrosion (Fig. 4.6 (b) right). The
failure modes of the compression test specimens were buckling-type failure of the core lamel-
las in the initial compression tests and in the tests after the ageing periods (Fig. 4.6 (d)). The
shear test specimens failed by a shear failure of the core but also by a core compression fail-
ure on a support and a wrinkling failure of the face. Thus, the failure mode shall be taken into
account in the analysis of the test results. Due to the time of the ageing the detachment of the
faces from the core was a reason of the failures of the shear test specimens (Fig. 4.6 (c)).
4.8 RW-3
Wrinkling failure in the small-scale wrinkling tests with rectangular samples took place in most
cases in the mid-span of the specimen, below the transversal loading beam. In the initial test
series, three specimens failed by a local buckling of the face at the lower end of the specimen.
A buckling failure close to the lower end was observed in one test, when testing the specimens
exposed to ageing for two weeks. A typical failure mode of the small-scale wrinkling test with
rectangular samples is shown in Fig. 4.7 (a), top. The bone-shaped wrinkling tests produced in
the majority of cases a failure by wrinkling, excluding some tests with failure at support (c.f.
Fig. 4.7 (a), bottom). Consequently, the latter were not taken into account. The failure modes
of the full-scale panels strongly diversify, including failure at support, wrinkling failure and
shear-failure as well as delamination failure (see Fig. 4.7 (b)). The difference of the failure
modes makes it very difficult to determine the wrinkling stress, it was even impossible for the
4-weeks-aged samples.
Failure modes of the cross-panel tension tests are shown in Fig. 4.7 (c). The tensile failure
taking place clearly inside the core layer in the initial tests and in the specimens exposed to
ageing for one and two weeks, moved lightly closer to the lower and upper face when the time
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No.: D4.2/2
of the exposure to the ageing increased to four and eight weeks. A failure mode of the com-
pression test is shown in Fig. 4.7 (e). The compression failure mode is typically an irregular
line caused by a crushing and buckling of the structural core lamellas of the core. The failure
mode of the shear test is shown in Fig. 4.7 (d). All the shear test specimens in the initial test
series failed by a buckling failure of the upper face below the loading beam. Thus, the initial
shear strength could not be measured, but the value calculated on the basis of the highest
load is an lower limit to the initial shear strength of the core. All other specimens with an ex-
ception of one specimen after the exposure to ageing for eight weeks, failed by the pure shear
failure modes of the core.
4.9 RW-4
Wrinkling failure in the small-scale wrinkling tests with rectangular specimens took place in
most cases in the initial tests in the mid-span of the specimen, below the transversal loading
beam. The failure modes outside the transversal loading beam area were also buckling waves
inward to the specimens. Due to the ageing, the failure mode changed to long buckling waves
directed outside the specimen, the reason for which was a detachment of the face and core
(c.f. Fig. 4.8 (a)). The bone-shaped wrinkling tests produced failure by wrinkling, excluding one
test with a failure at the support, the result of which was not taken into account. The failure
modes of the full-scale panels strongly diversify, including failure at support, wrinkling failure,
shear-failure as well as delamination failure (Fig. 4.8 (b)).
The failure mode of the cross-panel tension test specimens arose partially in the core and par-
tially in the bond close to the upper or the lower face. The failure mode remained similar in the
specimens, which were exposed to ageing (see Fig. 4.8 (d)). The failure mode of the cross-
panel compression test specimens was typically an irregular line caused by a crushing and
buckling of the structural core lamellas of the core. Due to the ageing, the long buckling-type
failures of the lamellas may be the more dominant failure mode (c.f. Fig. 4.8 (e)). All the shear
test specimens in the initial test series failed by a buckling failure of the upper face close to the
loading beam. Thus, the initial shear strength could not be measured, but the value calculated
on the basis of the highest load makes a lower limit to the initial shear strength of the core.
The shear test specimens exposed to ageing for one week failed through a buckling failure (2)
or crushing on a support (2), the specimens exposed to ageing for two weeks by buckling fail-
ure (2?) or crushing failure (3+2?), the specimens exposed to ageing for four weeks by buck-
ling failure (3), crushing failure (1) or by a shear failure (1) and the specimens exposed to age-
ing for eight weeks (see Fig. 4.8 (c)) by buckling failure (3+1?), crushing failure (2?) or by a
shear failure (1?). The question marks denote the second failure modes of the specimens on
the basis of a visual inspection.
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No.: D4.2/2
(a) Full-scale bending test
(c) Shear test
(b) rectangular and bone-shaped sample (d) Cross panel tensile test
Fig. 4.1: Overview of the failure modes for PU-1
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No.: D4.2/2
(c) Shear test
(b) rectangular and bone-shaped sample (d) Cross panel tensile test
Fig. 4.2: Overview of the failure modes for PU-2
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No.: D4.2/2
(b) bone-shaped sample
(c) Shear test
(d) Cross panel tensile test

Fig. 4.3: Overview of the failure modes for EPS-1
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No.: D4.2/2
(b) bone-shaped sample
(c) Shear test
(d) Cross panel tensile test

Fig. 4.4: Overview of the failure modes for EPS-2
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No.: D4.2/2
(a) rectangular and bone-shaped sample (b) Cross panel tensile test
(d) Shear test
(c) Compression test (e) Full-scale bending test

Fig. 4.5: Overview of the failure modes for RW-1
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No.: D4.2/2
8-weeks-aged
initial
(a) rectangular sample
8-weeks-aged
initial
(b) Cross panel tensile test
8-weeks-aged
initial
(c) Shear test
8-weeks-aged
initial
(d) Compression test

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No.: D4.2/2
(a) rectangular and bone-shaped sample (b) Full-scale bending test
(d) Shear test
(c) Cross panel tensile test (e) Compression test

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No.: D4.2/2
initial
8-weeks-aged
(a) rectangular sample (b) Full-scale bending test
initial 8-weeks-aged
(c) Shear test
initial
8-weeks-aged
8-weeks-aged
(d) Cross panel tensile test (e) Compression test

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No.: D4.2/2
5 Determination of the shear modulus and strength from the full scale tests
For reasons of comparison between the results measured in small-scale shear tests and in the
full scale wrinkling tests, the shear modulus was determined on the basis of the results of the
full-scale tests, also. Additionally, when having a uniform shear failure in the wrinkling test, the
shear strength was determined. In the diagrams at the end of this chapter the corresponding
curves are presented.
The shear modulus determined by small scale tests and the shear modulus determined from
the full-scale wrinkling tests of the PU 1 specimens (span= 3900 mm) agree to each other very
well (see Fig. 5.1). A comparison of the shear strength is not possible, because all the full
scale specimens failed by wrinkling.
The shear modulus curves of the PU-2 specimens (see Fig. 5.2) have an absolute difference
of 1 N/mm², a difference which is maybe caused by the subjective assessment when determin-
ing the slope from the curve (span of full-scale tests was 3900 mm). Also the shear strength
curves have a noticeable difference. But it has to be noticed, that while for 24 week-aged pa-
nels all specimens failed by a shear failure, in the initial tests as well as for the 12 week-aged
specimens there is in each case only one sole specimen that failed by a shear failure.
For the EPS-1 specimens (steel faced panels), the shear modulus curves have a maximum
difference of approx. 2 N/mm² for the 6 week aged specimens, but the other time-step values
are more closer to each other (span of full-scale tests was 3100 mm). Especially the initial
value and the final 12-week value are almost identical (see Fig. 5.3).
No full-scale wrinkling tests have been performed for the EPS-2 specimens (GRP-faced pa-
nels).
For the RW-1 samples, full-scale wrinkling tests with a span of 2880 mm as well as 3880 mm
have been performed and the results by the corresponding curves are presented in Fig. 5.4.
While the shear modulus determined from the 3880 mm-span-tests (light blue dashed curve)
and the shear modulus determined with small specimen tests (green dashed curve) conform to
each other, the shear modulus determined from the 2880 mm-span-tests (grey dashed curve)
have a noticeable difference to the others. A determination of the shear strength from the full
scale tests was not possible due to non-uniform shear failures in the tests.
Full scale tests with RW-2 samples have not been performed due to replacement of these
samples by RW-4.
For both shear modulus curves of the RW-3 specimens (c.f. Fig. 5.5) there is a good correla-
tion for the initial values and the 1-week values, an also the 4-weeks values have only a differ-
ence of approx. only 0.35 N/mm². Due to a non-uniform shear failure in the full-scale tests, a
comparison of the shear strength is not expedient (span of full-scale tests was 3880 mm).
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No.: D4.2/2
In Fig. 5.6 curves for the shear modulus and shear strength of the RW-4 specimens are pre-
sented. For both, the shear modulus and shear strength, there are some noticeable differenc-
es (span of full-scale tests was 3880 mm).
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No.: D4.2/2
PU-1: Comparison of shear modulus and strength

DUR 1 (75°C, RH<15 %)
(small specimen tests and full scale tests)
3,5 0,3
3
0,25
2,5
0,2
Modulus [N/mm2]
Strenght [N/mm2]
2
0,15
1,5
0,1
1
0,05
0,5
0 0
0 2 4 6 8 10 12 14 16 18 20 22 24
Shear modulus
Shear modulus (determined from full scale tests, span=3900 mm)
Shear strength
Shear strength (determined from full scale tests) [not available because all tests failed by wrinkling]
Fig. 5.1: Comparison of the shear strength and modulus of for PU-1 specimens
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PU-2: Comparison of shear modulus and strength

DUR 1 (75°C, RH<15 %)
4,5 0,3
0,25
3,5
3 0,2
Modulus [N/mm2]
Strenght [N/mm2]
2,5
0,15
1,5 0,1
0,05
0,5
0 0
0 5 10 15 20
Shear modulus
Shear strength
Shear strength (determined from full scale tests, span=3900 mm)
Fig. 5.2: Comparison of the shear strength and modulus of PU-2 specimens
page 50
of report
No.: D4.2/2
EPS-1: Comparison of shear modulus and strength

DUR 1 (75°C, RH<15 %)
8 0,3
7
0,25
0,2
5
Modulus [N/mm2]
Strenght [N/mm2]
4 0,15
3
0,1
0,05
1
0 0
0 2 4 6 8 10 12 14 16 18 20 22 24
Shear modulus
Shear strength
Shear strength (determined from full scale tests) [not available because all tests failed by wrinkling]
Fig. 5.3: Comparison of the shear strength and modulus of EPS-1 specimens
page 51
of report
No.: D4.2/2
RW-1: Comparison of shear modulus and strength

DUR 2 (65°C, RH>95 %)
6 0,05
0,045
5
0,04
0,035
4
0,03
Modulus [N/mm2]
Strenght [N/mm2]
3 0,025
0,02
2
0,015
0,01
1
0,005
0 0
0 2 4 6 8
Shear modulus
Shear strength
Shear strength (determined from full scale tests, span=2880 mm) [not available because no uniform shear failure]
Shear strength (determined from full scale tests, span=3880 mm) [not available because no uniform shear failure]
Fig. 5.4: Comparison of the shear strength and modulus of RW-1 specimens
page 52
of report
No.: D4.2/2

DUR 2 (65°C, RH>95 %)
4,1 0,10
0,09
4
0,08
3,9
0,07
0,06
Modulus [N/mm2]
Strenght [N/mm2]
3,8
0,05
3,7
0,04
0,03
3,6
0,02
3,5
0,01
3,4 0,00
0 2 4 6 8
Shear modulus
Shear strength
Shear strength (determined from full scale tests) [not available because no uniform shear failure]
page 53
of report
No.: D4.2/2

DUR 2 (65°C, RH>95 %)
14 0,10
0,09
12
0,08
10
0,07
0,06
Modulus [N/mm2]
Strenght [N/mm2]
8
0,05
6
0,04
0,03
4
0,02
2
0,01
0 0,00
0 2 4 6 8
Shear modulus
Shear strength
Shear strength (determined from full scale tests, span=3880 mm)
page 54
of report
No.: D4.2/2
6 Summary and conclusions
Work package WP4 of the EASIE project deals with retrofitting, durability and maintenance of
sandwich panels. The experimental part concerning the subject durability included tests with
small-scale and full-scale specimens in artificial ageing conditions in the climate chambers at
Aalto University School of Engineering (TKK), at Technische Universität Darmstadt (TUD) and
at Institut für Sandwichtechnik – FH Mainz (ISM) [1], [2], [3]. The test series included alto-
gether 1115 tests with polyurethane (PU), expanded polystyrene (EPS) and stone wool (RW)
cored sandwich panels. The faces of the specimens were made of steel sheets with the ex-
ception of EPS-2 specimens, the faces of which were made of glass fibre laminates. The ex-
perimental work concentrated to study the changes caused by the time, temperature and
moisture in the core and bond. However, the corrosion of the face sheets played a role in the
tests of RW-1 and RW-2 specimens.
In addition to the tests in climate chambers, also tests of sandwich panels exposed to natural
ageing conditions were performed. A monitoring of the four full-scale sandwich panels installed
in the outdoor test rig in Ingelheim Germany was made by ISM in June 2010 [3]. The tests
were started in 2002, thus the new results show the development of the rigidity of the test
panels during an eight years period. The strength and resistance and the thermal conductivity
of sandwich panels having been in service in walls and a roof in Karlsruhe, Germany for 23
years [4], [5] and in Traun, Austria for 30 years [6] were studied by Karlsruher Institut für
Technologie (KIT).
Evaluation of the influence of the ageing on sandwich panels is in this report based on sole
experimental results and observations on a macroscopic level. The internal physical-chemical
changes in the structure of the core materials and bonds have not been studied.
Results of the tests of the PU-cored specimens show that the most reductions of the strength
in the course of the time to an exposure to a high temperature take place in the cross-panel
tensile strength. Reductions can also be observed in the wrinkling stress of the faces and par-
tially in the shear strength of the core. The cross-panel compression strength tends to increase
with the time of the exposure. The ageing of the PU foam is partially caused by the diffusion of
the cell gases, which takes place quickly in small-size specimens such as in cross-panel ten-
sile and compression strength specimens, which are open in two dimensions. The diffusion is
much slower in large-size specimens such as in full-scale panels. Therefore, the time of the
exposure to ageing of the full-scale panels has been double compared to the small-size
specimens.
Test results of the EPS-cored specimens show also the reductions of the cross-panel tensile
strength being the highest. However, during a short time of the exposure, the cross-panel ten-
sile strength tends to increase due to the high temperature. Similar changes can be observed
in the wrinkling stress of the face. No changes or increases of the shear strength and of the
page 55
of report
No.: D4.2/2
cross-panel compression strength were measured in the ageing tests of the EPS-cored
specimens. The wrinkling stress of the glass-fibre laminate faced specimens decreases during
short periods to the exposure, which is a difference to the wrinkling stress of the steel sheet
faced and EPS cored specimens.
The cross-panel tensile strength of the RW-cored specimens shows the most reduction when
the specimens were exposed to a simultaneous high temperature and humidity. Reductions in
the cross-panel compression strength and in the shear strength were similar. Reductions of
the wrinkling stress followed the reductions of the compression and shear strength or were
smaller or even negligible. The change of the ideal wrinkling failure mode to a delamination
failure mode and the corrosion of the surfaces of the faces may have had influence in the
wrinkling stress of some of the RW-cored specimens. More information is still required about
the development of the shear strength, because of the partially missing initial shear strength
values.
The experimental study shows that the influence of the ageing depends on the sandwich panel
product. No general model can be written on the basis of the results and observations. There
is a connection between the cross-panel tensile strength, modulus of elasticity of the core and
the wrinkling stress. There is also a connection between the cross-panel tensile and compres-
sion strength and the shear strength through the material model of the core, which however, in
most cases are not isotropic.
There is still a link missing between the results created in the accelerated artificial laboratory
conditions and in natural outdoor conditions. Fast changes can be caused in the laboratory
conditions, in which the specimens are exposed to a high temperature and humidity. Test re-
sults on the old panels having been in service long times in outdoor conditions show an ac-
ceptable level of strength and resistance.
The EASIE project has received financial support from the European Community’s Seventh
Framework Programme FP7/ NMP2-SE-2008 under grant agreement No 213302.
page 56
of report
No.: D4.2/2
7 References
[1] Durability Tests performed at Aalto University School of Science and Technology
(TKK), Test report 4.1, Part 1, 2011, EASIE
[2] Durability Tests performed at Technische Universität Darmstadt (TUD), Test report
4.1, Part 2, 2011, EASIE
[3] Durability Tests performed at Institut für Sandwichtechnik - FH Mainz, Test report
4.1, Part 3, 2011, EASIE
[4] Test Report 4.2, Part 1, Testing of used panels, Wall panels (approx. 23 years old)
removed from a building in Karlsruhe, Germany, EASIE, Karlsruhe Institute of Tech-
nology (KIT), Versuchsanstalt für Stahl, Holz und Steine, 2011
[5] Test Report 4.2, Part 2, Testing of used panels, Roof panels (approx. 23 years old)
removed from a building in Karlsruhe, Germany, EASIE, Karlsruhe Institute of Tech-
nology (KIT), Versuchsanstalt für Stahl, Holz und Steine, 2011
[6] Test Report 4.2, Part 3, Testing of used panels, Wall panels (approx. 30 years old)
removed from an industrial building in Traun, Austria, EASIE, Karlsruhe Institute of
Technology (KIT), Versuchsanstalt für Stahl, Holz und Steine, 2011
[7] European Standard EN 14509, 2006. Self-supporting double skin metal faced insu-
lating panels. Factory made products. Specifications
[8] Retrofitting, Durability and Maintenance, Experimental programme, WP4 doc 2 rev 4,
EASIE
[9] Pfeifer, L. (2005) Durability Assessment of Sandwich Panel Construction, Doctor
Thesis, University of Surrey and Fachhochschule Mainz
[10] Baehre, R. (1988) Experimentelle Ermittlung der aufnehmbaren Knitterspannung von
ebenen und leicht profilierten Stahldeckschichten, Research Report, Universität
Karlsruhe
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EASIE - Model for effect of ageing

Technical Report · November 2011

Thomas Misiek Jörg Lange

SEE PROFILE SEE PROFILE

Application of the SPS-Technology in Short Span Railway Bridges View project

The user has requested enhancement of the downloaded file.

Model for effect of ageing

Publisher: Andreas Metzger, Saskia Käpplein, Thomas Misiek,

Task: 4.2 and 4.3

This report includes 56 pages.

Date of issue: 15 November 2011

Verification and approval

2 Overview of specimens, tests and test arrangements 4

3 Assessment of the test results and conclusions concerning the durability 8

4 Failure modes and developments during the ageing 34

6 Summary and conclusions 54

The Ensuring Advancement in Sandwich Construction through Innovation and Exploitation

2 Overview of specimens, tests and test arrangements

Cross Panel Tensile Test

Material Test Face Layer

inner face (steel core)

Small wrinkling test

Tests performed by:

3 Assessment of the test results and conclusions concerning the durability

PU-1: Comparison of the Results of the

Elasticity modulus in tensile test (Tests perfomed at TUD)

Wrinkling stress (small scale, rectangular sample)

Cross-panel tensile strenght

Elasticity modulus in tensile test

PU-2: Comparison of the Results

Elasticity modulus in tensile test (Tests perfomed at TUD)

Wrinkling stress (small scale, bone-shaped sample)

RW-1: Comparison of the Results of the

Elasticity modulus in tensile test (Tests perfomed at TKK)

Cross-panel tensile strength (Tests perfomed at TKK)

RW-2: Comparison of the Results of the

RW-3: Comparison of the Results of the

Elasticity modulus in tensile test (Tests perfomed at ISM)

Fig. 3.15: Relative development of strength and modulus of RW-4 specimens

RW-4: Comparison of the Results of the

Elasticity modulus in tensile test (Tests perfomed at ISM)

4 Failure modes and developments during the ageing

(a) Full-scale bending test

(c) Shear test

(a) Full-scale bending test

(c) Shear test

(a) Full-scale bending test

(b) bone-shaped sample

(c) Shear test

(d) Cross panel tensile test

(b) bone-shaped sample

(c) Shear test

(d) Cross panel tensile test

(d) Shear test

(c) Compression test (e) Full-scale bending test

(a) rectangular sample

(b) Cross panel tensile test

(c) Shear test

(d) Compression test

(a) rectangular and bone-shaped sample (b) Full-scale bending test

(d) Shear test