Institut für Sandwichtechnik - Mainz Institut für Sandwichtechnik - Mainz

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Projects

Projects

Running Projects

Research Assignment ZF4119601 Kl5
PCC-Tower (pre-cast concrete tower) Erforschung, Entwicklung und Erprobung eines neuartigen Betonfertigteil-Konzepts zum Bau von besonders hohen Windenergieanlagen, Onshore
Ziel des Vorhabens ist die Entwicklung sogenannter Hybridtürme für besonders hohe Windenergieanlagen mit Nabenhöhen >130m, um den international wachsenden Bedarf an qualitativ hochwertigen und dennoch kostengünstigen Betonfertigteiltürmen zu decken.
Anlass: Das PCC-Tower- Konzept favorisiert eine Fertigteillösung für das Betontragwerk und verfolgt zugleich einen neuen Ansatz, bei dem relativ kleine und leichte, in sich verzahnte Fertigteile in einem 2-stufigen, baustellennahen Produktionsverfahren hergestellt werden, wourch es sich sehr stark von existierenden Bauverfahren unterscheidet.
Die Hybridtürme bestehen aus einem extern vorgespannten Betontragwerk, auf dem ein Stahlturm aufgesetzt wird. Es sollen produktionstechnisch einfache, vergleichsweise kleinformatige, leicht montierbare Betonfertigteile zum Einsatz kommen. Diese können dezentral und somit baustellennah in herkömmlichen, d.h. in nicht spezialisierten Fertigteilwerken in Serie hergestellt werden, so dass große Transportdistanzen und die damit verbundenen Belastungen für Straßen, Verkehr, Umwelt und Polizei zukünftig entfallen.
Entwicklung: Ziel ist es, geeignete Fugen- und Verbindungskonstruktionen zu entwickeln und zu erproben, welche den bemessungsrelevanten Anforderungen aus den statischen und dynamischen Einwirkungen Rechnung tragen.

The following project partners are involved with this research project:

  • Tubularis GmbH
  • Betonwerk Hachmeister GmbH, Andernach
  • i3mainz, Institut für Raumbezogene Informations- und Messtechnik
  • Zentrales Innovationsprogramm Mittestand, Bundesministerium für Wirtschaft und Technologie

Contact person: Prof. Dr.-Ing. Andreas Garg

 



Completed Projects

Research Assignment 17003X10
SandFast - Development and optimization of practical fastenings of sandwich panels by design special solutions This research project deals with the optimization of practical fastenings of sandwich panels. Firstly, the economic proof of interaction for tensile and shear forces is to be determined for direct fastenings.  The aim of this research project is the optimization of joint geometry using FEM-simulation to increase the load-bearing capacity of indirect (hidden) fixings. Within statically indetermined multi-span systems sandwich panels are constrained due to temperature differences. By developing practical flexible fastenings, the load-bearing capacity of the sandwich panels is to be increased. The project was funded by BMBF in a term of 2.5 years. The official start of the research project has been 01 July 2010.

The following project partners are involved with this research project:

  • EJOT Baubefestigungen GmbH
  • Fischer Profil GmbH
  • Hilti AG
  • REISSER-Schraubentechnik GmbH
  • Roma Dämm-Systeme
  • SOFiSTiK Service GmbH
  • Universität Karlsruhe KIT
  • Technische Universität Darmstadt
  • ThyssenKrupp Bausysteme GmbH
  • Trimo (Slowenien)

Contact person: Dipl.-Ing. Katrin Kilian

 



Research Assignment 1790X09
SwichCore II - Research and improval of the Fire-resistance of the core materials of sandwich-panels
The research project SwichCore II deals with research and improval of the fire-resistance of the core materials for sandwich-panels. Within the previous research project SwichCore new materials were developed. Two of those materials will be optimised in SC II.
The two materials are phenolic-foam and hybrid-foam based on EPS (SiAC). Additionally to these testings PIR, a polyurethan with improved fire-behavior, will be tested.
The testing within this project is about the mechanical properties as well as the fire behavior, especially fire resistance.
Another main focus is the design of joints, which have a big influence on the fire-resistance of panels.
The project is financed by the Bundesministerium für Bildung und Forschung (BMBF) and has a running time of 2,5 years (July 1st. 2009 to December 31st. 2011).

The partners of the project are:

  • BASF
  • Brucha
  • Fischer Profil
  • Hexion Specialty Chemicals
  • Metecno Bausysteme
  • M-Profil
  • Resolco International BV
  • Romakowski
  • Siempelkamp Handling Systeme
  • Technische Universität Darmstadt
  • ThyssenKrupp Steel
  • Trimo d.d.

 



Project Number FP7-NMP-2007-SME-213302
EASIE – Ensuring Advancement in Sandwich construction through Innovation and Exploitation

The European research project is situated in the Commissions 7th Framework Programme and had its official starting date at October 1st, 2008. The project gets 19 partners from 10 nations to work together on current subjects in sandwich technology. The EASIE research was initiated by ECCS TWG 7.9 and is coordinated at iS-mainz. The EU grant agreement was signed in early December 2008. More detailed information about the project can be found at www.easie.info.

 



Research Assignment 1764X08
SandSet - Research into Sandwich elements as self-supporting structural members

The research project addresses the applicability of sandwich panels as self-supporting structural members without substructure. The studies comprise the development of fastenings to ensure the transition of loads into the sandwich structure. This includes the fastenings of sandwich panels among each other as well as the fastening of wall and roof panels. A design method shall be derived. By saving the substructure both production costs and assembly time are reduced. New ways of application of sandwich panels will be established. The project is funded by the BMBF. Scheduled processing time is 3 years. The project started July 1st, 2008.

 



Research Assignment 1786X07
DiFuSe -
Research and Development of tight joints for sandwich panels used in steel light-weight constructions
It is the primary object of the research project to investigate the tightness of joints in constructions made of sandwich elements. Hence, guidelines for the design of new joints shall be derived. For this purpose it is essential to know in detail the basic parameters for the conveyance of air, water and heat energy through the joints. The project was financed by the “Bundesministerium für Bildung und Forschung (BMBF)“.
Starting date was the 1st of March 2007 and the project was finished in August 2009. The final research report can be obtained via Fraunhofer IRB (search word: Sandwichtechnik)

The Research Assigment DiFuSe II is already applied.

 



Research Assignment 1705X06
SandTweak - Optimisation of geometry and core material of sandwich panels with metallic faces
Funded by German Ministry for Education and Research
Due to their numerous advantages more and more sandwich panels are used. Aim of the SandTweak project is to adjust the face geometry together with the properties of the core material in such way that bearing capacity, costs, properties concerning construction physics, environmental compatibility and production engineering are optimised.
Reduction of material and production costs needs scientifically sound optimisation processes first. The history of trapezoidal steel sheets could be used for comparison here because their cross-section geometry has been developed on the basis of extensive testing in order to obtain optimal bearing capacity and minimal material consumption at the same time. Thus, an optimisation of sandwich panels in a comparable way would be of great benefit.
This topic is very extensive, because of the numerous parameters which determine bearing capacity, properties concerning construction physics and production costs. At first it seems to be quite difficult to implement an optimisation of sandwich panels. On the other hand optimised structural members are very important for the whole sandwich industry.
Within this research project a doctoral thesis and a final paper will be prepared. Furthermore students will have the chance to write seminar papers within the SandTweak project.
The research project officially started on 1st September 2006 and it was scheduled to run for two years.
In detail the following partners participated in the project:

  • University of Applied Sciences Mainz, represented by the Institute for Sandwich Technology (Project leader)
  • Technical University Darmstadt (Technical consulting)

The SandTweak project at the Institute for Sandwich Technology were supported by numerous industrial partners:
Sandwich panel producers:

  • ECP Gesellschaft für GFK-Systemlösungen mbH
  • Fischer Profil GmbH
  • Romakowski Dämmsysteme
  • ThyssenKrupp Hoesch Bausysteme
  • Fischer Profile
  • Trimo Engineering d.d. (Slovenia)

Producers of core materials for sandwich panels:

  • BASF AG
  • Bayer Material Science
  • Deutsche Rockwool Minerawoll-GmbH
  • JACKON Insulation GmbH
  • Saint - Gobain Isover - Orsil (Czech Republic)

Producers of manufacturing plants for sandwich panels:

  • SHS Siempelkamp

 



Research Assignment FH³ 1709X05
SandFlat - “Research and development into flat roof sandwich elements
Funded by German Ministry for Education and Research
The aim of the SandFlat project is to find an alternative to traditional flat roofs with the thermal insulation on the external side as used for flat roofs in industrial buildings. The alternatives are special flat sandwich panels. In this connection it is especially important that the new sandwich elements are equipped with flat upper sides. Such new development could strongly improve the share of sandwich roof elements in the total volume of all roof elements in industrial buildings. The adoption of such a novel building element helps manufacturers of sandwich panels and the producers of core materials for sandwich panels to ensure the actual market positions and to expand this position compared to other European business competitors. Such grants are particularly important for small and medium-sized companies in the building industry.
In this project it was very important to focus research on the development of sealings. For the practical joint geometry appropriate sealing geometries needed to be found, which must guarantee a durable impermeability and simple mounting.
Starting date was the 1st of September 2005 and the project was finished in late 2008. The final research report can be obtained via Fraunhofer IRB (search word: Sandwichtechnik)

The following partners were involved in the project:

  • Hochschule Mainz, represented through the Institute for Sandwich Technology (Project leader)
  • Technical University Darmstadt, Department Civil Engineering and Geodesy (Technical consulting)

The research consortium was completed by a variety of sandwich panel producers:

  • Fischer Profile GmbH
  • Isobouw Dämmsysteme GmbH
  • Izopoli Yapi Elementari (Turkey)
  • Kingspan Germany GmbH
  • Paroc Panel System OY AB (Finland)
  • Romakowski Dämmsysteme GmbH & Co. KG
  • ThyssenKrupp Hoesch Building Systems
  • Trimo d.d (Slovenia)

Producers of sealing systems:

  • illbruck Bau-Technik GmbH
  • Schmid Baukunststoffe GmbH

Producers of fastening systems:

  • SFS intec GmbH & Co. KG, Fastening Systems

 



Research Assignment KF0224601GZ5
PrePreg - standardisation of a prepreg recycling process: determination and evaluation of mechanical properties of a new construction product providing the base for a technical approval
Supported by: BMWA
The latest development is based on a large quantity of material available from the producers of wind energy plants. Such wind mills are often made from high quality fibre reinforced plastics, namely Prepreg, a woven fibre mat soaked with epoxy resin. The resin is hindered from polymerisation reaction through a protective layer. Only when this layer is removed, the reaction starts and the polymer cures. If not used in a recycling process, the Prepreg remains from the windmill production industry is cost-intensive waste that needs disposal and is obliged to production of supporting documents.
Currently the provided waste is used in a provisional production of plastic boards. These bordas have however little value to the market and are currently mainly used as protection boards in chemically highly aggressive environments, such as stables, an application far underestimating the structural ability of the recycling material and far from being optimized in terms of production process and material composition.
It is the aim of this project to introduce this high quality recycling material to a more advanced application which exploits more of the potential of the product. The Project was supported by the German Ministry for economy affairs and employment. Starting date for the project was the 1st of December 2005 and the project was finished in December 2008.

Project partners were:

  • Schmid Baukunststoffe GmbH (project leader)
  • Technische Universität Cottbus, represented through the Institut für Produktionswirtschaft
  • Hochschule Mainz, represented through the Institute for Sandwich Technology
  • Barsmark A/S (provider of prepreg recycling material)

 



Research Assignment FH³ 1705X04
SwichCore - “Development of a new fire resistant core material for sandwich panels”
Funded by German Ministry for Education and Research
The fire resistance and fire performance of sandwich panels is becoming more and more important. This is particularly true for the British market, but also for the rest of Europe and where the issue has not come up yet it will surely be an issue before long. It is therefore desirable for any sandwich producer to have a core material on hand for relevant applications. iS-mainz has therefore decided to put research effort into the development of fire improved foam systems for continuous sandwich production. A research grand was applied for. In July 2004 iS-mainz has received the positive answer from the German Ministry for Education and Research to start the SwichCore research programme. It is the aim of the programme to develop a new core material for sandwich panels. Starting date was the 1st of October, the project was scheduled to run for two years. The research concentrated on Phenolic foams, but also tackled other foam based core materials such as hybrids. The final research report can be obtained via Fraunhofer IRB (search word: Sandwichtechnik).

The following partners were involved in the project:

  • Hochschule Mainz, represented through the Institute for Sandwich Technology (Project leader)
  • Bakelite AG (Worldwide active producer of Phenolic resins from Düsseldorf, Germany)
  • LMK, the Institute for Lightweight Constructions from Moscow in Russia
  • Siempelkamp Handling Systems

The research consortium was completed by a variety of sandwich panel producers. In detail these were:

  • Romakowski Dämmsysteme
  • ThyssenKrupp Hoesch Bausysteme
  • Fischer Profile
  • Metecno Bausysteme
  • Trimo Engineering
  • Eurobond Ltd.

The Research Assigment SwichCore II is already applied.

 



Research Assignment ASPAN GRD2-2000-30043
“Durability Assessment of Sandwich Panels intended to be used for Roof Covering and Wall Finishes”

Funded by European Union
This project funded by the EU under the Craft V programme investigates into the long term behaviour of sandwich panel constructions. During the discussions concerning an European standard for sandwich panels in CEN/TC 128 SC11, which is now available (EN 14509) it was found necessary to gather more information on the durability behaviour of sandwich panels.
It was therefore found necessary to call for a research project investigating both, experimentally and theoretically into this problem. Partners in this project come from France, Finland, Great Britain, Spain and Italy. It was the task of Hochschule Mainz to investigate into old panels in order to find a time lapsing investigation method. The project was scheduled to last two years and was finished in late spring 2004.
Furthermore climatic effects on panels are studied in an erected outside testing rig near Ingelheim in Germany.

The ASPAN research project has come to an end and the final research report is now available. It can be purchased from the project leader (Advanced Research Partnership) by sending a short e-mail.
The report is in English language.
The table of contents can be seen here.

 



Research assignment P32-5
“Determination of a possible safety deficit comparing design procedures as described in German approval to the upcoming European standard”
Funded by Deutsches Institut für Bautechnik (German approval body)
It was the aim of this project to find a possible safety deficit of the newly available European standard prEN 14509 when being compared to the currently in Germany compulsory approvals which are issued by the Deutsches Institut für Bautechnik. The project was started in March 2003 and finished in October of the same year.

 



Research assignment Brite….
“Development of a novel building unit for commercial and domestic buildings”
Funded by European Union
The project was started in 1999 and is financed by the European Union. The project was finalized in 2003. Together with University partners as well as small and medium sized enterprises from Great Britain, Denmark and Ireland an innovative, frameless construction method based on the sandwich principle was developed and investigated. The research has lead to a useable construction method. Hochschule Mainz has developed the corresponding design method based on the results of experimental investigation. Currently numerous buildings are erected and iS-mainz is accompanying a Dutch company providing consulting for problems of minor extend. A special focus is drawn on detail solution and openings.

 



Aluminium-plastic compound profiles
Aluminium –plastic compounds have for long tome been used in conservatory construction. The plastic insertion here minimizes the heat transport through the girder, minimizing heat bridges. In a static model the soft compound between plastic and aluminium as well as the interaction of shear and bending forces need to be accounted for. This can be cone analogue to sandwich theory. For the first time experimental investigation dealing with these problems was undertaken. A design method has been developed. The generated testing methods are now compulsory for German approvals.

 


Hidden fixings for steel sandwich elements
In co-operation with industry new hidden fixing methods for sandwich panels were developed and tested. It is particularly here that a variety of different parameters determine the load bearing capacity of the construction. In a variety of test series different solutions were found and optimized. In this field co-operation with a variety of companies was established.

 


Push-out testing on concrete compound structures
A testing series commissioned by industry to investigate the influence of coatings on steel sheets in concrete-steel compound structures was run. So far it had been assumed that the adhesion of steel sheet and concrete was caused by the geometry of the steel sheet exclusively. With the help of so called “push-out” testing this was proven to be wrong. The surface characteristics of the steel have a decisive influence. Based on the outcome of these tests, industry could take appropriate steps to ensure proper linkage between steel and concrete.

 


Aluminium honeycomb core
For a German approval for an isolated case (Zustimmung im Einzelfall) aluminium sandwich elements with a honeycomb shaped core were investigated. The necessary testing was undertaken in co-operation with the Amtliche Prüfstelle für Baustoffe.

 


Archive

By popular request we offer Information about the
"Exhibition of current projects" on 28/05/2004

05/28/2004 - The Institute for Sandwich Technology presents itself
Exhibition of current projects
In a comprehensive exhibition the Institute for Sandwich Technology – Mainz presented its currently investigated projects. The event took place in the Aula (assembly room) of Hochschule Mainz.
At the same time the 38th general assembly of Panama International, a worldwide union of panel producers, was held in Hyatt Mainz. All participants were invited to visit the exhibition.



 

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