Technical Guide Ver2.0

The Royal Building System
TECHNICAL GUIDE
Version 2.0 The ULTIMATE Concrete Forming Technology
Royal Building Systems (Cdn) Limited www.rbsdirect.com

Technical Guide
TABLE OF CONTENTS
1. INTRODUCTION 1.1 1.2 The Royal Building System About The Technical Guide
2. MATERIALS 2.1 2.2 Polymer Concrete 2.2.1 Concrete Take-off 3. CODE APPROVALS AND TECHNICAL PUBLICATIONS 4. PRODUCT PERFORMANCE 4.1 4.2 4.3 4.4 4.5 4.6 Weatherability of Royalloy B Fire Performance of Royalloy B Fire Performance of Concrete-Filled RBS Walls Acoustic Performance of Concrete-Filled RBS Walls Energy Performance Indoor Air Quality 4.6.1 Off-Gassing 4.6.2 Mold & Mildew 4.7 Termites
5. STRUCTURAL TESTING
Version 2.0 - July 1999 Copyright 1999, Royal Building Systems (Cdn) Limited

Technical Guide
6. STRUCTURAL DESIGN 6.1 6.2 RBS Wall System as a Non-Structural Formwork RBS Wall System as a Structural Wall Assembly 6.2.1 Concrete Strength 6.2.2 Wall Openings and Concentrated Loads 6.2.3 Wall Lintels APPENDIX A Wall and Lintel Design Tables in Metric Units APPENDIX B Wall and Lintel Design Tables in Imperial Units
Copyright 1999 Royal Building Systems (Cdn) Limited. All rights reserved. No part of this publication may be reproduced in any form or by any means without written permission from Royal Building Systems (Cdn) Limited. The Royal Building System is a registered trademark of Royal Building Systems (Cdn) Limited. Royalloy is a trademark of Royal Building Systems (Cdn) Limited. RBS DIRECT! is a trademark of Royal Building Systems (Cdn) Limited. AutoCAD is a registered trademark of Autodesk, Inc.

Technical Guide
1. INTRODUCTION 1.1 The Royal Building System
Welcome to the world of Royal Building Systems (Cdn) Limited, an innovative quality-driven building technologies company. Since the introduction of The Royal Building System in 1992, Royal has received global recognition for its approach in providing innovative solutions to the residential, commercial, industrial, institutional, agricultural, and construction sectors. The Royal Building System is a patented, proprietary concrete forming technology that combines advanced composite materials, leading-edge extrusion processes and concrete. The result is permanent and attractive structures that can be easily constructed in any climate. The Royal Building System utilizes a superior form of extruded, reinforced polymer components with characteristics that surpass the performance criteria of conventional building materials. The polymer components used in The Royal Building System will not decay or deteriorate over a life expectancy that can be measured in decades. The System also requires no painting, resists ultraviolet radiation and does not support combustion. Furthermore, The Royal Building System is highly durable, virtually maintenance free, impervious to weather, and extremely energy efficient. The Royal Building System is also environmentally friendly as the polymer components are recyclable, energy efficient and non-toxic. Put it all together, and you can see that The Royal Building System offers complete design flexibility in an innovative building technology that is easy to maintain, friendly to the environment and built to last. Whether you are a contractor, designer, architect or engineer, we believe you will find interesting solutions for your next project.
Building SOLUTIONS for a Better World

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Technical Guide
1.2
About The Technical Guide
This Technical Guide has been prepared by Royal Building Systems (Cdn) Limited as a tool to assist builders, contractors, engineers, and architects in understanding and designing structures using The Royal Building System technology. It is a part of our continuing effort to provide current and practical information to users of The Royal Building System. The Technical Guide provides information on the following aspects of The Royal Building System: Material Properties Code Approvals Product Performance Structural Testing Structural Design
In addition to the Technical Guide, the following guides are also available to assist in designing and building your projects using The Royal Building System technology. Design & Software Guide Typical Details Guide Construction Guide
Although every effort has been made to ensure that all the information provided in the Technical Guide is factual and that the numerical values are accurate and consistent with current engineering practice, Royal Building Systems (Cdn) Limited does not assume any liability for errors or oversights resulting from the use of information contained in this guide. Anyone making use of the information provided in these guides assumes all liability arising from such use. All suggestions for improvement of these guides will be given full consideration for future revisions.
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2. MATERIALS
The Royal Building System (RBS) consists of extruded rigid polymer components that serve as a formwork for concrete walls including load bearing walls, non-load bearing walls (i.e., curtain walls), shear walls, wall lintels, retaining walls, and foundation walls. The extruded components slide and interconnect together to create a concrete formwork that remains in place after the concrete is poured and cured. The RBS wall components are extruded in three widths as identified in Table 2.1. Table 2.1: RBS Wall Systems
Wall Thickness Wall System RBS4 RBS6 RBS8i Overall 100 mm (4") 150 mm (6") 200 mm (8") Concrete Core 95 mm (4") 145 mm (6") 139 mm (6") Insulation1 0 0 54 mm (2")
2.1
Polymer
The primary material used in the design of The Royal Building System is Royalloy B. Royalloy B is a rigid polymer (polyvinyl chloride-based) composite material that has been specifically blended to produce a unique set of properties suitable for the weatherability and performance of The Royal Building System. The physical properties of Royalloy B were established based on the very detailed requirements specified by the Canadian Construction Materials Centre (CCMC). To meet CCMC's requirements, a comprehensive program of tests was conducted. Chemically, Royalloy B is a complex composition of polyvinyl chloride resin, acrylic modifiers, waxes, lubricants, tin stabilizer (lead stabilizers are not used), ultraviolet ray protectant, and smoke and flame suppressants. The resulting compound has a cell classification of 1 20023 32 0040, as per ASTM 4216. Materials properties of Royalloy B are shown in Table 2.2.
The RBS8i wall system is pre-insulated with 54 mm (2") of polyurethane insulation. The insulation cavity is on the exterior side of the wall and protected from the interior with the non-combustible concrete core.
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Table 2.2: Materials Properties of Royalloy B

Property Specific gravity Heat deflection temperature (load 1.82 MPa) annealed at 65C Coefficient of linear expansion D696 ASTM Test Method Code Requirement2 D792 D648 report value > 70 C > 158 F < 6 x 10-5 cm/cm/C < 3.3 x 10-5 in/in/F max 3 report value > 37.7 MPa > 5500 psi > 2800 MPa > 377000 psi report value report value report value report value report value 80 5 > 53.4 > 1.0 report value Results 1.47 75 C 167 F 5.8 x 10-5 cm/cm/C 3.2 x 10-5 in/in/F 1.3 25 40.0 MPa 5750 psi 3725 MPa 540200 psi 2.5 % 127 % 70.9 MPa 10280 psi 3537 MPa 513000 psi 102 81 96.1J/m 1.8 ft-lb/in 4982 J/m 1.12 in-lb/mil
Shrinkage (1/2 hr @ 82 C) Ash content Tensile strength Tensile modulus Elongation at yield Elongation at break Flexural strength Flexural modulus Hardness (Rockwell) Hardness (Shore D) Notched Izod impact resistance Drop dart impact (Procedures A & B)
D3679 D229 D638 D638 D638 D638 D790 D790 D785 D2240 D256 D4226
Unless otherwise noted, these are the CCMC requirements for The Royal Building System.
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2.2
Concrete
The second most important material used in the design of The Royal Building System is concrete. Concrete comprises more than 90% (by mass and volume) of the RBS Walls. Concrete with the following minimum specifications should be utilized: Minimum 28-day compressive strength 20 MPa (2900 psi) Maximum aggregate size 10 mm (3/8"), p-gravel Minimum slump 115 mm (4 ") at the point of discharge
Concrete does not segregate in the RBS Walls due to the inner webs of the Box Connectors and Panel components, which act like an elephant trunk and therefore prevent the free-fall of heavier aggregates. Honeycombing should not occur if concrete is placed correctly with a specified slump of 115 mm (4 "). Concrete does not normally need to be vibrated. However, a rubber mallet may be used to tap the sides of the walls to ensure that the components are completely filled with concrete.
2.2.1 Concrete Take-off

The theoretical quantities of concrete for various RBS Walls are shown in Table 2.3 (Metric units) and Table 2.4 (Imperial units). Note that the actual quantity of concrete must be adjusted for wall openings, wastage, and specific project conditions. Table 2.3: Concrete Take-off (Metric Units) RBS4
Per Cubic Metre of Concrete Per Square Metre of Wall Area 11.1 m
2
RBS6
Square Metre of Wall Area 7.2 m2 Cubic Metre of Concrete 0.1385 m3
RBS8i
7.5 m2 0.1336 m3
0.0903 m3
Table 2.4: Concrete Take-off (Imperial Units) RBS4

Per Cubic Yard of Concrete Per Square Foot of Wall Area 91 ft
2
RBS6
Square Foot of Wall Area 59 ft2 Cubic Yard of Concrete 0.0169 yd3
RBS8i
61 ft2 0.0164 yd3
0.0110 yd3
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3. CODE APPROVALS AND TECHNICAL PUBLICATIONS

The Royal Building System has been approved in the USA and in over twenty countries worldwide including Argentina, Canada, China, Japan, and Mexico. Numerous technical papers and engineering reports have also been produced. The following is a brief summary of the major code approvals and technical papers: BOCA The Royal Building System has been evaluated by BOCA-ES in accordance with the BOCA National Building Code (BOCA-ES Report No 94-57). CCMC The Royal Building System has been evaluated by CCMC in accordance with the National Building Code of Canada (CCMC Evaluation Report 12536-R). BMEC The Royal Building System has been authorized by the Building Materials Evaluation Commission (Ontario) to be used as non-load bearing walls in commercial and industrial applications, with unlimited building area (BMEC Authorization #A1997-21). OBC Ruling of the Ontario Minister of Housing, in accordance with Ontario Building Code (Ruling No. 95-01-20-(12536-R)). 1999 The Royal Building System: Thermal Performance, Energy Consumption, and Code, a technical report prepared by Trow Consulting Engineers and reviewed by Dr Eric Burnett, Director, Pennsylvania Housing Research Center (Trow Report No T99-01). 1998 Penn State Research Report No 51. Ranked the RBS8i Wall System as the best foundation wall system out of 8 different products evaluated. ASCE 1997 Technical Paper presented at the Annual Conference of American Society of Civil Engineers in Minneapolis. ASCE 1996 Technical Paper presented at the Annual Conference of American Society of Civil Engineers in Washington DC. Also as detailed in Section 5 of this guide, numerous structural tests have been conducted on the Royal Building System. Based on these tests, Royal has demonstrated compliance of The Royal Building System with the design loads of the BOCA National Building Code (BOCA), the Uniform Building Code (UBC), the Standard Building Code (SBC), the South Florida Building Code (SFBC), and the National Building Code of Canada (NBCC).
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4. PRODUCT PERFORMANCE 4.1 Weatherability of Royalloy B
Royalloy B has been specifically designed to resist fading and discoloration due to weathering. Accelerated weathering tests (Table 4.1), as well as outdoor weathering tests (Table 4.2) have been conducted. Table 4.1: Weathering Properties of Royalloy B Accelerated
Property Yellowness Index Color Retention (Hunter Units) Units YI YI E L a b Drop Dart Impact % Retention D1925 E313 D2244 D2244 D2244 D2244 D4226
4 3
ASTM Test Method
Results + 2.15 + 1.87 + 0.98 - 0.34 + 0.01 + 0.92 97
Table 4.2: Weathering Properties of Royalloy B Outdoor

ASTM Test Property Yellowness Index Color Retention (Hunter Units) Units YI YI E L D1925 E313 D2244 D2244 D2244 D2244 D4226 Arizona 1.16 0.98 0.54 -0.19 - 0.05 0.50 88.1 0.09 0.19 0.48 0.12 - 0.15 0.12 81.3
Results Chicago - 0.35 - 0.26 0.18 - 0.08 - 0.04 - 0.15 100.0 - 0.18 - 0.16 0.93 - 0.89 - 0.01 - 0.02 100.0
Florida - 0.16 - 0.13 0.64 - 0.60 - 0.01 - 0.16 92.7 - 0.49 - 0.39 0.49 - 0.26 - 0.03 - 0.25 96.0
Method 6 months 1 year 6 months 1 year 6 months 1 year
a b Drop Dart Impact % Retention
Notes:
ASTM D1925 discontinued in 1995 Color changes are in Hunter units YI change in yellowness index E total color change L change in lightness/ darkness direction a change in red/ green direction b change in yellow/ blue direction
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2000-Hour accelerated weathering tests conducted in accordance with ASTM G53. Outdoor weathering conducted in accordance with ASTM D1435.
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4.2
Fire Performance of Royalloy B
The fire performance of Royalloy B is shown in Table 4.3. The testing was conducted to satisfy BOCA, CCMC, and other code approval agencies. Note that for reference and comparison purposes the properties of wood are also shown. Table 4.3: Fire Performance of Royalloy B
Test Method ASTM D1929 ASTM D1929 ASTM D635 ASTM D635 Code Requirement 5 min 343 C (US) 650 F Flash-ignition temperature Rate of burn Maximum extent of burning none none 10 mm/sec 0.394 in/sec max 25.4 mm (US) 1.0 in max 25 (US) < 150 max 450 (US) report value none Results 480 C 896 F 460 C 860 F 0 0 12.4 mm 0.49 in 19 13 261 75 None Wood 208-2646 406 507 2605 500 NA NA NA NA 100 NA 380 NA 34 117
Fire Performance Self-ignition temperature
Flame spread Smoke Development Flash Fire Propensity (time to flash fire in seconds)
ASTM E84 ULC S102.2 ASTM E84 ULC S102.2 Footnote 6
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CCMC requirements for The Royal Building System, unless otherwise noted. White Pine, Hildo, C.J., Flammability Handbook for Plastics, Third Edition, 1982, Published by Westport Conn. Red Oak, Hildo, C.J., Flammability Handbook for Plastics, Third Edition, 1982, Published by Westport Conn.
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4.3
Fire Performance of Concrete-Filled RBS Walls
RBS walls are a composite wall system having a structural base of noncombustible concrete. In accordance with the definition provided in Section 703.4.2 of the International Building Code (final draft), RBS walls are considered noncombustible. Note that similar definitions are provided in the BOCA and UBC codes as well. Thus, the fire resistance rating of RBS walls would be similar to that of a concrete wall. Nonetheless, to confirm that the polymer webs do not impact the fire resistance performance, RBS concrete-filled walls have been tested and evaluated for fire resistance. Additionally, RBS walls have also been exposed to various fire tests for evaluation of performance of the exterior face of the walls. Following is a summary of the full-scale fire tests conducted: CAN/ULC S101, Standard Methods of Fire Endurance Tests of Building Construction and Material (Equivalent to ASTM E119). Based on this test the fire resistance rating of RBS has been confirmed. The ratings are shown in Table 4.4. CAN/ULC S101, 15-minute remain-in-place test. This test allows the RBS walls with external insulation and stucco finish on the exterior face to be used as exterior walls in noncombustible construction. CAN/ULC S134, Standard Method of Fire Test of Exterior Wall Assemblies. This test method provides an assessment of fire spread, vertically and horizontally, on the exterior face of non-loadbearing exterior wall assemblies. This method evaluates the performance of the cladding of a wall from fire exposure resulting from a post-flashover fire in a compartment venting through an opening in the wall.
Table 4.4: Fire Resistance of RBS Walls

Wall System RBS4 RBS6 RBS8i Overall Thickness 100 mm (4") 150 mm (6") 200 mm (8") Concrete Core Thickness 95 mm (4") 145 mm (6") 139 mm (6") Minimum Fire Resistance 45 minutes8 2 hours9 2 hours8
8 9
Based on Engineering study and the fire test described in footnote 9. Based on the fire testing conducted on a vertically reinforced (10M bars at 333 mm o/c) and horizontally reinforced (10M bars at 333 mm o/c) RBS6 wall assembly; the test was conducted at ULC (Underwriters Laboratory of Canada) in accordance with the Canadian Standard CAN/ULCS101-M89 (equivalent to ASTM E119).
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4.4
Acoustic Performance of Concrete-Filled RBS Walls
Almost all building codes require that walls separating dwelling units from each other or from public or service areas have a Sound Transmission Class (STC) of not less than 50 (or 45 if field tested). STC is established in accordance with ASTM E90, Standard Test Method for Laboratory Measurement of Airborne Sound Transmission Loss of Building Partitions and Elements. Whereas field testing is conducted in accordance with ASTM E336, Standard Test Method for Measurement of Airborne Sound Insulation in Buildings. The acoustic testing of the RBS Walls was conducted in accordance with ASTM E336. Based on this test, the sound transmission of The Royal Building System is summarized in Table 4.5. A FSTC rating of 45 is considered equivalent to a STC rating of 50. Table 4.5: Sound Transmission Rating of RBS Walls
Wall System RBS4 RBS6 RBS8i Overall Thickness 100 mm (4") 150 mm (6") 200 mm (8") FSTC Rating 48 47 53 Equivalent STC Rating 54 53 58
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4.5
Energy Performance
Three major factors affecting the thermal performance of a wall system are thermal bridging, air tightness of the enclosure, and thermal mass. The combined effect of these factors is generally not considered when comparing the thermal performance of a building system. Normally, a simple R-value is quoted. Studies have shown that the simple comparison of quoted R-values is not an appropriate method of comparing the thermal performance of different building systems. This form of overly simplistic evaluation is neither correct nor fair for all systems that employ thermal mass and thermal insulation to their advantage. Thermal Bridging is caused by wood or steel members, especially in light-frame construction. These members can act as a thermal bridge causing heat flow to shortcircuit. Unlike The Royal Building System, framed systems can suffer from severe thermal bridge heat loss, especially at corners, windows and partitions. For instance, a 2 x 6 wood framed wall with a drywall interior finish and vinyl siding can be shown to have a nominal R-value of 21.5 (using R19 batt). When the extra thermal bridging inherent in framing around doors and windows is accounted for, ASHRAE10 considers such a wall to have an R-value of 13.7. Therefore, a 2 x 6 wall system would not meet the requirements of the ASHRAE standard for residential buildings in colder regions such as Michigan, or North Dakota. Air leakage through the building enclosure can be a major source of energy loss, approximately 30% to 50%. Airtight buildings use far less energy through the building envelope. The RBS walls provide a tighter building envelope compared to many conventional building systems, without the use of an additional air barrier. For instance, RBS4 wall system (4" concrete-filled wall) has an air leakage rate of 0.020 L/(s m2) at a pressure differential of 75 Pa. This is the same level of airtightness required from a 6 mil thick sheet of polyethylene when used as air barrier. However, this is much better than the tightest air barrier system with an air leakage rate of 0.05 L/(s m2) required by the National Building Code of Canada. Thermal mass effect in RBS walls is provided by the thermally insulated concrete. This thermal mass effect provides for significantly lower space-conditioning energy consumption when compared to lightweight wall systems with the same nominal Rvalue. In some climates, the effective R-value of an RBS wall will be twice that of framed wall insulated to the same nominal level.
10
The American Society of Heating, Refrigerating and Air-Conditioning Engineers, is an international organization of 50,000 persons with chapters throughout the world. The Society is organized for the sole purpose of advancing the arts and sciences of heating, ventilation, air conditioning and refrigeration for the public's benefit through research, standards writing, continuing education and publications. ASHRAE writes standards that set uniform methods of testing and rating equipment and establish accepted practices for the HVAC&R industry worldwide, such as the design of energy efficient buildings.
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Researchers at Oak Ridge National Laboratory (ORNL) have also investigated the effect of thermal mass on annual energy consumption in a range of US climates. Employing the same representative, one-story ranch-type house, the ORNL researchers modeled the space-conditioning energy consumption over a typical year for houses with both lightweight and massive walls. The base house in all cases had a lightweight roof assembly insulated to R30. The contribution of air leakage was assumed to be the same for all homes. Table 4.5: Whole-House Mass Benefits of RBS Walls in Various Climates
ORNL Estimated Equivalent R-value for: R12 Walls R14.5 Walls1 R19 Walls2 (RBS4 or RBS6 + 2" of (RBS4 or RBS6 + 2 " (RBS4 or RBS6 + 3 " EXP) EXP or RBS8i) of EXP) 25.3 30.6 41.7
1
City Atlanta Denver Miami Minneapolis (similar to Toronto) Phoenix Washington (similar to Vancouver)
22.5 26.4 17.9 30.8 21.6
27.3 29.1 21.7 37.1 25.9
35.9 47.3 28.5 47.7 35.5
1. The ORNL values are based on a wall with " drywall, 4" of solid concrete, and R12 exterior insulation (total R-value of 13.0). The RBS4 or RBS6 walls with 2" (steady-state R12) or 2 " (steady-state R14.5) of EXP (extruded polystyrene) sheathing or RBS8i walls with 2 1/8" of integrated polyurethane insulation (at least steady-state R14.6) have slightly more or less exterior insulation and interior thermal mass. 2. These ORNL values are based on a wall with 1/2" drywall, 6" of solid concrete, and R16 exterior insulation. The RBS4 or RBS6 walls with 3.5" of extruded polystyrene sheathing have slightly more exterior insulation and the same or slightly less interior thermal mass.
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4.6
Indoor Air Quality (IAQ)
In recent years, Indoor Air Quality (IAQ) has become a serious concern, especially due to off-gassing and mold growth in houses and schools. The resulting poor IAQ has serious health implications. Epidemiological studies from the U.K., the Netherlands, Sweden, and Canada have consistently shown negative health effects associated with dampness and mold. In children, symptoms most commonly associated with mold include respiratory problems, aches and pains, diarrhea, and headaches. In adults, the symptoms can include aching joints, nausea and vomiting, backache, blocked nose, and breathlessness. As discussed in the following subsections, The Royal Building System does not contribute to poor IAQ, but further enhances the IAQ by providing a building system that does not off-gas and that is mold and mildew resistant.
4.6.1 Off-Gassing
Testing and chamber studies11 have been conducted to assess the Indoor Air Quality of The Royal Building System homes12. The objective was to assess the contribution of volatile organic compounds (VOC), or off-gassing, associated with the extruded PVC building components to the concentration of the total VOC (TVOC) found in the indoor air. Based on the testing and analysis, the following was concluded: The average TVOC concentration found in three model homes was less than 0.3 mg/m3. This is significantly less than 1.0 2.0 mg/m3 typically found in occupied houses and offices. Chamber studies indicated that in the worst case scenario (a house built using the RBS system and occupied only one month after the building components were extruded representing the maximum amount of off-gassing from the new material), the concentration of 0.04 g/L (mg/m3) would contribute less than 15% to the TVOC found in the model homes. Note that the concentration of 0.04 mg/m3 is reaching the limit of analytical detection. The off-gassing from the extruded Royal Building System components is significantly less than the off-gassing associated with conventional building products such as: natural wood, laminated wood, particle board, various walls covering, etc.
11
12
Chamber testing of the extruded RBS building components was conducted in June 1997. For a complete report, please refer to Alara Report #9736, dated August 18, 1997 Indoor air-quality tests were conducted in January, 1997. For more details, please refer to Alara Report #9701, dated February 11, 1997.
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No health hazards or discomfort has been associated with the TVOC levels found in the three model homes.
4.6.2 Mold and Mildew

The growth of biological pests is assisted and promoted by wet building materials such as gypsum wallboard and wood. These conventional building materials get wet through absorption of water from high indoor humidity (condensation caused by thermal bridging), through moist air leaking through the building envelope and depositing its moisture before exiting the envelope, or simply by rain/ground water penetrating the interior of the building. The Royal Building System does not promote or allow the growth of mold and mildew as moisture does not penetrate the interior, and because the polymer surface does not absorb and store moisture. Even high indoor humidity levels do not damage the interior of the building, as the polymer surface of the wall is moisture resistant and vapor impervious.
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4.7
Termites
Termites are wood eating insects that live in organized communities. There are two basic types of termites, those that live entirely in wood, and those that can tunnel into the ground, also known as subterranean termites. The latter is the most destructive insect to the structure of a building. Each year in North America, termites cause billions of dollars of damage to buildings. According to University of California Pest Management Guidelines, termites are the most destructive wood-destroying insects in the USA. At least 1% of the housing units in the USA require treatment each year for the control of termites. As shown in the map below, more than half of the USA is infested with termites. Termites are beginning to appear in the colder climates of the Northern USA and Southern Canada. Recognizing this problem, building codes are requiring protection against termites to be considered in the design of foundation walls.
Figure 4.1: Termite Infestation Probability Map

Prevention is one of the three major ways of protecting against termites. The other two being remediation (treating soil with termiticide, a chemical control) and suppression (this method aims at killing some or all of the members of a colony).
Copyright 1998, International Code Council (ICC), Falls Church, Virginia. International One- and TwoFamily Dwelling Code/1998. Reproduced with the permission of the author. All rights reserved.
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Prevention can be achieved by proper design and the selection of a termite resistant material that is not prone to cracking and that does not contain concealed entry points for termites to enter the building. Conventional materials and construction methods, specifically wood framing, have not been able to achieve effective prevention. Similarly, cracking of concrete foundations (concrete block and cast-in-place concrete) provides concealed entry points for termites. All of these problems, which lead to termite vulnerability, are effectively eliminated by The Royal Building System. Furthermore, the System remains impregnable over time. Even if settlement or seismic activity causes cracking of the concrete, the cracks are never accessible to termites as all of the concrete is uniformly encased in the durable polymer shell.
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5. STRUCTURAL TESTING
The Royal Building System is a result of many years of research and development. Considerable testing has been conducted both "in-house" and through third parties. Royal has retained the services of several independent accredited testing laboratories, technical experts, and product evaluation agencies, to conduct numerous testing programs on various aspects of The Royal Building System and to prepare engineering and evaluation reports. Testing on The Royal Building System has been conducted in many countries around the world, including the USA, Canada, Argentina, Guam, Japan, and China, for local approvals and performance evaluation of the System. Following is a brief list of some of the structural tests conducted: Gravity load testing (simulating snow loads), Pressurization testing (simulating high wind loads), Lateral load testing (simulating earthquake loading), and Testing of two full-scale prototype houses (to establish performance of all wall and roof members and their interconnections).
Based on the above testing, Royal has demonstrated compliance of The Royal Building System with the design loads of the BOCA National Building Code (BOCA), the Uniform Building Code (UBC), the Standard Building Code (SBC), the South Florida Building Code (SFBC), and the National Building Code of Canada (NBCC). These tests demonstrated that The Royal Building System performs extremely well in high winds and has excellent seismic response, with failure, if any, being localized and with little or no debris. Note that concrete is reinforced by the polymer shell, which also provides confinement for the concrete during extreme seismic activity.
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6. STRUCTURAL DESIGN
The RBS wall systems are composed of cored box connector and panel components. The components are interlocked and filled with concrete to form a monolithic wall. Vertical and horizontal steel reinforcing bars are added, as required, for additional strength and stiffness. The wall components are extruded in three widths: 100 mm (4"), 150 mm (6"), and 200 mm (8"), The RBS8i wall system is pre-insulated with 54 mm (2 1/8") of polyurethane insulation. The RBS walls can be designed using two different methods: RBS wall system is used as non-structural stay-in-place formwork RBS wall system is used as a concrete-filled structural wall assembly
6.1
RBS Wall System as a Non-Structural Formwork
If the polymer shell of the RBS wall system is considered to be a non-structural component of the wall, the RBS wall system provides a stay-in-place formwork and provides a finished wall. Under this scenario, one can conservatively ignore the significant contribution of the polymer shell of RBS wall to the strength of the wall and concrete is reinforced by the addition of steel reinforcing bars. Thus, the structural design of the walls is performed in conformance with local building codes and local concrete design standards. For instance, in the USA, the applicable design standard is ACI 318, Building Code Requirements for Structural Concrete. In Canada, the applicable design standard is CSA Standard A23.3, Design of Concrete Structures. When designing slender walls, second-order analysis should be performed, considering material non-linearity and cracking, as well as the effects of member curvature and lateral drift, duration of the loads, shrinkage and creep, and interaction with the supporting foundation. A suggested software program to perform this analysis, is PCA-WALL, Structural Analysis and Design of Slender Concrete Walls, developed by the Portland Cement Association.
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6.2
RBS Wall System as a Structural Wall Assembly
If the polymer shell of the RBS wall system is considered to be a structural component of the wall, the RBS wall system provides the formwork, the wall finish, and the reinforcement for the concrete. The use of the polymer shell as a structural component to reinforce concrete is a new concept that is not presented in existing design standards. Royal Building Systems (Cdn) Limited has performed extensive testing to study the interaction between the polymer and the concrete. The results of the testing indicate that the polymer has a significant capacity to act as tension reinforcement for the concrete. The compression stresses in the wall are resisted by the concrete and the tension stresses in the wall are resisted by the polymer. The structural design of the wall is performed in conformance with empirical design methods that are suggested based on the testing. The empirical methods are used to calculate the factored resistance values for use in Limit States Design or Load Resistance Factor Design (LRFD). The values for Working Stress Design or Allowable Stress Design (ASD) are calculated by dividing the factored resistance values by 1.5. The dead load factor is 1.25 (0.85 for load reversal); a factor of 1.5 is used for live, earthquake, and wind loads. The following equations are provided such that calculation can be performed in metric or imperial units. However, units cannot be mixed. Please decide on the preferred unit system and stay consistent throughout the entire design process. When using the LRFD approach, the factored moment resistance (in metric or imperial units) is calculated using the following equation: Mr = (0.8)(0.5) (Fu)(Sx) .................................................................................. (1) 0.8 0.5 Fu Sx is the permissible stress factor for temperature/load duration of the polymer is the resistance factor of the polymer (strength reduction factor) is the ultimate tensile strength of the polymer in MPa or psi is the section modulus of the polymer in mm3 or in3
The factored shear resistance (LRFD) is calculated as follows: Using metric units Vr = (0.2)(0.6)( f ' c )(Ac) x 10-3 [kN] ............................................................ (2m)
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Technical Guide
Using imperial units Vr = (2.408)(0.6)( f ' c )(Ac) [lbf] .................................................................... (2i) 0.6 is the resistance factor for concrete (strength reduction factor) f'c is the 28 day specified strength of concrete in MPa or psi Ac is the area of concrete in mm2 or in2 The factored axial load resistance (in metric or imperial units) is calculated as follows. Pr = (0.45)(0.6)(fc)(Ac)(1-( 0.6 f'c Ac Lc t 0.8 L c 2 t ) ), for an eccentricity < .......................... (3) 32 t 6
is the resistance factor for concrete (strength reduction factor) is the 28 day specified strength of concrete in MPa or psi is the area of concrete in mm2 or in2 is the vertical clear distance between supports in mm or in is the effective thickness of the wall in mm or in
If the structural design using the polymer alone is not adequate for the applied tensile loads, reinforcing steel bars are added to the wall. In this case, the structural design is performed as noted in Section 6.1, RBS Wall System as a Non-Structural Formwork. The reinforcing steel bars are designed for the total load under consideration, since the modulus of elasticity of steel is 55 times greater than the modulus of the polymer and all of the tension stresses will be resisted by the steel. Based on this approach, to assist designers, architects and engineers, design tables showing the physical properties, flexural resistance, and axial load resistance have been developed. The design tables using metric units are shown in Appendix A and those using imperial units are included in Appendix B.
6.2.1 Concrete Strength

Concrete with a minimum specified (28-day) strength of 20 MPa (2900 psi) is suggested. For concrete exposed to freeze thaw conditions, the use of concrete with the minimum specified strength of 25 MPa (3600 psi) is recommended. Refer to Section 2.2 for further information on concrete specifications. Higher strength concrete may be used as required by design. Minimum reinforcement Unless required due to loads, wall geometry or other special conditions, the minimum reinforcing bars for walls of small structures, such as single family residences, are recommended as follows:
6-3

Technical Guide
Design Wind Speed not greater than 80 mph and exposure condition Type B or Seismic Risk Zone not greater than 1 (av < 0.05) Dowels to foundation at 1000 mm (3' - 3") on center, maximum, for a one level structure or the upper level of a two level structure. Dowels to lower level at 667 mm (2' - 2") on center, maximum, for the lower level of a two level structure. Vertical bars, 15M (#5), at exterior corners and at roof beams.
Design Wind Speed not greater than 100 mph and exposure condition type B or Seismic Risk Zone greater than 1 but not greater than 2 (0.05 < av < 0.10) Dowels to foundation at 667 mm (2' - 2") on center, maximum, for a one level structure or the upper level of a two level structure. Dowels to lower level at 333 mm (1' - 1") on center, maximum, for the lower level of a two level structure. Vertical bars, 15M (#5), at exterior corners and at roof beams.
Design Wind Speed not greater than 120 mph and exposure condition type B or Seismic Risk Zone greater than 2 but not greater than 4 (0.10 < av < 0.20) Dowels to foundation at 333 mm (1' - 1") on center, maximum, for a one level structure or both levels of a two level structure. Vertical bars, 15M (#5), at exterior corners, at wall intersections, at roof beams, at each side of all wall openings and at 2000 mm (6' - 7") on center, maximum.
6.2.2 Wall Openings and Concentrated Loads

Unless required due to loads, wall geometry or other special conditions, the minimum horizontal widths for the design of walls adjacent to wall openings or at concentrated loads in small buildings, such as single family residences, are recommended as follows: The width of wall adjacent to openings should be a minimum 767 mm (2 - 6). The width of wall under concentrated loads should be a minimum 1433 mm (4 - 8), or one third of the wall height, nor twice the width from the load to the end of a wall.
6-4

Technical Guide
6.2.3 Wall Lintels

The lintels over openings in the RBS walls are constructed with steel reinforcing bars to provide a reinforced concrete lintel, or with a structural steel member to provide a steel lintel. The reinforced concrete lintels are designed in accordance with ACI 318 or CSA Standard A23.3, with no contribution from the polymer component. The steel lintels to suit RBS walls are designed in accordance with the AISC Specification for Structural Steel Buildings (USA) or CSA-S16.1 (Canada). Steel conforms to ASTM A441, Grade 44 and CSA Standard G30.12M, Grade 300W. The physical and strength properties of steel lintels in metric units are provided in Appendix A and those in imperial units are provided in Appendix B.
6-5

Technical Guide
APPENDIX A: Wall and Lintel Design Tables (Metric Units)
A-1

Technical Guide
Physical Properties of the RBS4 Wall System

The RBS4 wall system is composed of 100 mm (4") thick cored box connector components and cored panel components. The members are interlocked and filled with concrete. Vertical and horizontal steel reinforcing bars can be added as required for additional strength and stiffness. The physical properties of the RBS4 wall system are shown in Table A1.
Table A1: Physical Properties of RBS4 Wall System, per metre

mass kg/m Polymer [1] Concrete [2] Composite Wall System [3]
2
A mm
2 6
Ix 10 mm 15.56 67.82 n/a

4
Sx 10 mm 311.2 1428.9 n/a

3 3 9
EIx 10 N.mm 56.0 1364.8 [4] 134.0 [5]

2
r mm 47.05 27.40 27.76
t mm 100.0 94.9 96.2 [6]
12.1 220.2 232.3
7029 90322 100000
Values are based on the polymer web thickness, tdesign = 1.83 [1] Royalloy B: E = 3600 MPa; Fu = 40 MPa; Acoring = 3299 mm2 [2] Normal weight concrete: E = 20125 MPa; f'c = 20 MPa [3] Composite member [4] Stiffness of uncracked section [5] Stiffness of composite cracked section [6] teff is based on radius of gyration of uncracked section
A-2

Technical Guide
Strength Properties of the RBS4 Wall System

The RBS4 wall system can be used as a structural member to support gravity loads and lateral loads. The strength properties per metre of the wall system, shown in Tables A2 and A3, are calculated assuming that the compression stresses in the wall are resisted by the concrete and that the tension stresses in the wall are resisted by the polymer. Table A2: Factored Strength Properties, per metre
weight kN/m2 Polymer [1] Concrete [2] Composite Wall System [3] 0.12 2.16 2.28 A mm2 7029 90322 100000 Mr kN.m 4.98 [4] 1.53 [5] 4.98 [6] Vr Vertical kN n/a n/a 17.0 [7] Vr Horizontal kN n/a n/a 48.5 [8] t mm 100.0 94.9 96.2 [9] EIx 109 N.mm2 56.0 1364.8 [10] 134.0 [11]
Table A3: Factored Axial Load Resistance for Unsupported Height Lc [12], per metre
Lc (mm) 0.0 2053 2220 2386 2553 2636 2720 Pr (kN) 487.7 348.8 325.3 300.1 273.0 258.8 243.9 Lc (mm) 2803 2886 2970 3053 3136 3220 3303 Pr (kN) 228.8 213.3 197.1 180.6 163.7 146.1 128.2 Lc (mm) 3386 3470 3553 3636 3720 3803 3847.2 Pr (kN) 109.9 91.0 71.7 52.1 31.7 11.1 0.0
Values based on Laboratory Test Reports, Empirical Rules, CAN3-A23.3-M94 and ACI 318-95. [1] [2] [3] [4] [5] [6] [7] Royalloy B; E = 3600 MPa; Fu = 40 MPa; Acoring = 3299 mm2 Normal weight concrete; E = 20125 MPa; f'c = 20 MPa Composite member -6 Mr = (0.8)(0.5)(Fu)(Sx) x 10 where 0.8 is the temperature/load duration factor Mr = (0.4)(0.6)( f ' c )(Sx) x 10-6 Mr for the cracked section is governed by the polymer Vr = (0.2)(0.6)( f ' c )(Ac vertical)(0.8) x 10-3, where Ac vertical = 12 x 3299 mm2; 0.8 is the effective coring area factor [8] Vr = (0.2)(0.6)( f ' c )(Ac horizontal) x 10 , where Ac horizontal = 90322 mm
-3 2
[9] teff is based on radius of gyration of uncracked section [10] Stiffness of uncracked section [11] Stiffness of composite cracked section [12] Pr = (0.45)(0.6)(fc)(Ac)(1-(
0.8 L c 2 t -3 ) )x 10 for e < , t = teff 32 t 6
A-3

Technical Guide

The RBS6 wall system is composed of 150 mm (6") thick cored box connector components and cored panel components. The members are interlocked and filled with concrete. Vertical and horizontal steel reinforcing bars can be added as required for additional strength and stiffness. The physical properties of the RBS6 wall system are shown in Table A4.
Table A4: Physical Properties of RBS6 Wall System, per metre

mass kg/m Polymer [1] Concrete [2] Composite Wall System [3]
2
A mm
2 6
Ix 10 mm 37.33 242.39 n/a

4
Sx 10 mm 497.7 3345.2 n/a

3 3 9
EIx 10 N.mm 134.4 4878.1 [4] 310.0 [5]

2
r mm 71.54 41.84 42.21
t mm 150.0 144.9 146.2 [6]
13.1 338.6 351.7
7293 138498 150000
Values are based on the polymer web thickness, tdesign = 1.83 [1] Royalloy B: E = 3600 MPa; Fu = 40 MPa; Acoring = 5847 mm [2] Normal weight concrete: E = 20125 MPa; f'c = 20 MPa [3] Composite member [4] Stiffness of uncracked section [5] Stiffness of composite cracked section [6] teff is based on radius of gyration of uncracked
2
A-4

Technical Guide

The RBS6 wall system can be used as a structural member to support gravity loads and lateral loads. The strength properties of the wall system, shown in Tables A5 and A6, are calculated assuming that the compression stresses in the wall are resisted by the concrete and that the tension stresses in the wall are resisted by the polymer. Table A5: Factored Strength Properties, per metre
Lc (mm) 0.0 2720 2970 3220 3470 3720 3970 Pr (kN) 747.9 586.1 555.0 521.2 484.6 445.3 403.3 Lc (mm) 4220 4386 4553 4720 4886 5053 5220 Pr (kN) 358.5 327.3 294.7 260.8 226.0 189.7 152.2 Lc (mm) 5386 5470 5553 5636 5720 5803 5848.7 Pr (kN) 113.7 93.7 73.7 53.4 32.6 11.7 0.0
Values based on Laboratory Test Reports, Empirical Rules, CAN3-A23.3-M94 and ACI 318-95, [1] [2] [3] [4] [5] [6] [7] Royalloy B; E = 3600 MPa; Fu = 40 MPa; Acoring = 5847 mm2 Normal weight concrete; E = 20125 MPa; f'c = 20 MPa Composite member -6 Mr = (0.8)(0.5)(Fu)(Sx) x 10 where 0.8 is the temperature/load duration factor Mr = (0.4)(0.6)( f ' c )(Sx) x 10-6 Mr for the cracked section is governed by the polymer Vr = (0.2)(0.6)( f ' c )(Ac vertical)(0.8) x 10 , where Ac vertical = 12 x 5847 mm ; 0.8 is the effective coring area factor [8] Vr = (0.2)(0.6)( f ' c )(Ac horizontal) x10 , where Ac horizontal = 138498 mm
-3 2 -3 2
0.8 L c 2 t -3 ) )x 10 for e < , t = teff 32 t 6
A-5

Technical Guide
Physical Properties of the RBS8i Wall System

The RBS8i wall system is composed of 200 mm (8") pre-insulated cored box connector components and cored panel components. The members are interlocked and filled with concrete. Vertical and horizontal steel reinforcing bars can be added as required for additional strength and stiffness. The physical properties of the RBS8i wall system are shown in Table A7.
Table A7: Physical Properties of RBS8i Wall System, per metre

mass kg/m2 Polymer
[1]
A mm2 10620 133577 200000
Ix 106 mm4 73.29 214.79 n/a
Sx 103 mm3 628.2 3092.5 n/a
EIx 109 N.mm2 263.85 4322.7 [4] 292.4 [5]
r mm 83.08 40.10 41.02
t mm 200.0 138.9 142.1 [6]
18.6 326.7 348.0
Concrete [2] Composite Wall System [3]
Values are based on the polymer web thickness, tdesign = 1.83 [1] Royalloy B: E = 3600 MPa; Fu = 40 MPa; Acoring = 5847 mm [2] Normal weight concrete: E = 20125 MPa; f'c = 20 MPa [3] Composite member (foam mass density = 2.7 kg/m2, foam area = 51255 mm2) [4] Stiffness of uncracked section [5] Stiffness of composite cracked section [6] teff is based on radius of gyration of uncracked
2
A-6

Technical Guide
Strength Properties of the RBS8i Wall System

The RBS8i wall system can be used as a structural member to support gravity loads and lateral loads. The strength properties of the wall system, shown in Tables A8 and A9, are calculated assuming that the compression stresses in the wall are resisted by the concrete and that the tension stresses in the wall are resisted by the polymer. Table A8: Factored Strength Properties, per metre
Lc (mm) 0 2720 2970 3220 3470 3720 3970 Pr (kN) 721.3 556.1 524.3 489.8 452.4 412.3 369.3 Lc (mm) 4220 4386 4553 4720 4886 5053 5220 Pr (kN) 323.6 291.7 258.4 223.8 188.2 151.1 112.8 Lc (mm) 5386 5470 5553 5636 5683 Pr (kN) 73.5 53.1 32.7 11.9 0.0
Values based on Laboratory Test Reports, Empirical Rules, CAN3-A23.3-M94 and ACI 318-95, [1] [2] [3] [4] [5] [6] [7] Royalloy B; E = 3600 MPa; Fu = 40 MPa; Acoring = 5847 mm2 Normal weight concrete; E = 20125 MPa; f'c = 20 MPa Composite member (foam weight = 0.026 kN/m2, foam area = 51225 mm2) Mr = (0.8)(0.5)(Fu)(Sx) where 0.8 is the temperature/load duration factor Mr = (0.4)(0.6)( f ' c )(Sx) Mr for the cracked section is governed by the polymer Vr = (0.2)(0.6)( f ' c )(Ac vertical)(0.8), where Ac vertical = 12 x 5847 mm2; 0.8 is the effective coring area factor [8] Vr = (0.2)(0.6)( f ' c )(Ac horizontal), where Ac horizontal = 133577 mm
2
0.8 L c 2 t ) ) for e < , t = teff 32 t 6
A-7

Technical Guide
Steel Lintels
Steel lintels are designed in accordance with the AISC Specification for Structural Steel Buildings or CSA-S16.1 (Canada). Steel conforms to ASTM A441, Grade 44 or CSA Standard G30.12M, Grade 300W. As shown in the following drawings, steel lintels are fabricated from structural steel angles and plates. For RBS4 wall system, TEE 106x9.5x74 and TEE 133x12.7x77 are used. For RBS6 and RBS8i wall systems, 2 ANGLES 89x64x6.4 and TEE 133x12.7x115 are used.
TEE 106 x 9.5 x 74
TEE 133 x 12.7 x 77
2 ANGLES 89 x 64 x 6.4
TEE 133 x 12.7 x 115
Table A10: Physical and Strength Properties of Steel Lintel

Mass
kg/m
A
mm
2
Ix
x 10 mm
6 4
Sx
x 10 mm
3 3
Mr
kN.m
Br
kN
Vr
kN
For RBS4 concrete-filled Walls TEE 106x9.5x74 TEE 133x12.7x77 2 ANGLES 89x64x6.4 TEE 133x12.7x115 11.9 1510 1.60 23.81 6.43 17.0 2173 3.68 46.64 12.59 For RBS6 and RBS8i concrete-filled Walls 14.6 22.1 1850 2823 1.50 4.51 24.71 51.92 6.67 14.02 23.80 25.20 26.90 32.80 154 261 183 261
A-8

Technical Guide
APPENDIX B: Wall and Lintel Design Tables (Imperial Units)
B-1

Technical Guide

The RBS4 wall system is composed of 100 mm (4") thick cored box connector components and cored panel components. The members are interlocked and filled with concrete. Vertical and horizontal steel reinforcing bars can be added as required for additional strength and stiffness. The physical properties of the RBS4 wall system are shown in Table B1.
Table B1: Physical Properties of RBS4 Wall System, per foot

mass lbf/ft Polymer [1] Concrete [2] Composite Wall System [3] 2.5 45.1 47.6
2
A in
2
Ix in
4
Sx in
3
EIx 10 lbf.in 5.95 144.94 [4] 14.23 [5]

6 2
r in 1.85 1.08 1.09
t in 3.94 3.74 3.79 [6]
3.32 42.67 47.24
11.40 49.67 n/a
5.79 26.57 n/a
Values are based on the polymer web thickness, tdesign = 0.072 in [1] Royalloy B: E = 0.522 x 10 psi; Fu = 5800 psi; Acoring = 5.11 in [2] Normal weight concrete: E = 2.918 x 106 psi; f'c = 2900 psi [3] Composite member [4] Stiffness of uncracked section [5] Stiffness of composite cracked section [6] teff is based on radius of gyration of uncracked section
6 2
B-2

Technical Guide

The RBS4 wall system can be used as a structural member to support gravity loads and lateral loads. The strength properties of the wall system, shown in Tables B2 and B3, are calculated assuming that the compression stresses in the wall are resisted by the concrete and that the tension stresses in the wall are resisted by the polymer. Table B2: Factored Strength Properties, per foot
weight lbf/ft2 Polymer [1] Concrete [2] Composite Wall System [3] 2.5 45.1 47.6 A in2 3.32 42.67 47.24 Mr lbf.ft 1119 [4] 344 [5] 1119 [6] Vr Vertical lbf n/a n/a 1165 [7] Vr Horizontal lbf n/a n/a 3323 [8] t in 3.94 3.74 3.79 [9] EIx 106 lbf.in2 5.95 144.94[10] 14.23 [11]
Table B3: Factored Axial Load Resistance for Unsupported Height Lc [12], per foot
Lc (ft) 0.0 6.00 6.33 6.67 7.00 7.33 7.67 Pr (kips) 33.41 25.87 25.02 24.01 23.15 22.16 21.10 Lc (ft) 8.00 8.33 8.67 9.00 9.33 9.67 10.33 Pr (kips) 20.01 18.88 17.67 16.45 15.19 13.84 11.07 Lc (ft) 10.67 11.00 11.33 11.67 12.00 12.33 12.63 Pr (kips) 9.58 8.08 6.54 4.90 3.27 1.59 0.0
Values based on Laboratory Test Reports, Empirical Rules, CAN3-A23.3-M94 and ACI 318-95, [1] Royalloy B: E = 0.522 x 106 psi; Fu = 5800 psi; Acoring = 5.11 in2 [2] Normal weight concrete: E = 2.918 x 106 psi; f'c = 2900 psi [3] Composite member [4] Mr = (0.8)(0.5)(Fu)(Sx)/12 where 0.8 is the temperature/load duration factor [5] [6] [7] Mr = (4.817)(0.6)( f ' c )(Sx)/12 Mr for the cracked section is governed by the polymer Vr = (2.408)(0.6)( f ' c )(Ac vertical)(0.8), where Ac vertical = 3.657 x 5.11 in2; 0.8 is the effective coring area factor [8] Vr = (2.408)(0.6)( f ' c )(Ac horizontal), where Ac horizontal = 42.67 in2
0.8 L c 2 t -3 ) )x 10 for e < , t = teff, Lc = unsupported height in inches 32 t 6
B-3

Technical Guide

The RBS6 wall system is composed of 150 mm (6") thick cored box connector components and cored panel components. The members are interlocked and filled with concrete. Vertical and horizontal steel reinforcing bars can be added as required for additional strength and stiffness. The physical properties of the RBS6 wall system are shown in Table B4.
Table B4: Physical Properties of RBS6 Wall System, per foot

mass lbf/ft2 Polymer [1] Concrete [2] Composite Wall System [3] 2.7 69.4 72.1 A in2 3.45 65.43 70.86 Ix in4 27.34 177.53 n/a Sx in3 9.26 62.21 n/a EIx 106 lbf.in2 14.27 518.05 [4] 32.92 [5] r in 2.82 1.65 1.66 t in 5.91 5.71 5.76 [6]
Values are based on the polymer web thickness, tdesign = 0.072 in [1] Royalloy B: E = 0.522 x 106 psi; Fu = 5800 psi; Acoring = 9.06 in2 [2] Normal weight concrete: E = 2.918 x 106 psi; f'c = 2900 psi [3] Composite member [4] Stiffness of uncracked section [5] Stiffness of composite cracked section [6] teff is based on radius of gyration of uncracked section
B-4

Technical Guide

The RBS6 wall system can be used as a structural member to support gravity loads and lateral loads. The strength properties of the wall system, shown in Tables B5 and B6, are calculated assuming that the compression stresses in the wall are resisted by the concrete and that the tension stresses in the wall are resisted by the polymer. Table B5: Factored Strength Properties, per foot
weight lbf/ft2 Polymer [1] Concrete [2] Composite Wall System [3] 2.7 69.4 72.1 A in2 3.45 65.43 70.86 Mr lbf.ft 1789 [4] 807 [5] 1789 [6] Vr Vertical lbf n/a n/a 2062 [7] Vr Horizontal lbf n/a n/a 5091 [8] t in 5.91 5.71 5.76 [9] EIx 106 lbf.in2 14.27 518.05 [10] 32.92 [11]
Lc (ft) 0.0 10.00 10.50 11.00 11.50 12.00 12.50 Pr (kips) 51.23 37.33 35.91 34.42 32.85 31.22 29.52 Lc (ft) 13.00 13.50 14.00 14.50 15.00 15.50 16.00 Pr (kips) 27.74 25.90 23.99 22.01 19.96 17.84 15.65 Lc (ft) 16.50 17.00 17.50 18.00 18.50 19.00 19.20 Pr (kips) 13.40 11.07 8.67 6.20 3.67 1.06 0.0
Values based on Laboratory Test Reports, Empirical Rules, CAN3-A23.3-M94 and ACI 318-95, [1] Royalloy B: E = 0.522 x 106 psi; Fu = 5800 psi; Acoring = 9.06 in2 [2] Normal weight concrete: E = 2.918 x 106 psi; f'c = 2900 psi [3] Composite member [4] Mr = (0.8)(0.5)(Fu)(Sx)/12 where 0.8 is the temperature/load duration factor [5] [6] [7] Mr = (4.817)(0.6)( f ' c )(Sx)/12 Mr for the cracked section is governed by the polymer Vr = (2.408)(0.6)( f ' c )(Ac vertical)(0.8), where Ac vertical = 3.657 x 9.06 in2; 0.8 is the effective coring area factor [8] Vr = (2.408)(0.6)( f ' c )(Ac horizontal), where Ac horizontal = 65.43 in2
0.8 L c 2 t -3 ) )x 10 for e < , t = teff, Lc = unsupported height in inches 32 t 6
B-5

Technical Guide
Physical Properties of the RBS8i Wall System

The RBS8i wall system is composed of 200 mm (8") pre-insulated cored Box Connector components and cored Panel components. The members are interlocked and filled with concrete. Vertical and horizontal steel reinforcing bars can be added as required for additional strength and stiffness. The physical properties of the RBS8i wall system are shown in Table B7.
Table B7: Physical Properties of RBS8i Wall System, per foot

mass lbf/ft Polymer
[1]
2
A in
2
Ix in
4
Sx in
3
EIx 10 lbf.in 28.02 459.07 [4] 31.05 [5]

6 2
r in 3.27 1.58 1.61
t in 7.87 5.47 5.59 [6]
3.8 66.9 71.3
5.02 63.10 94.48
53.68 157.31 n/a
11.68 57.51 n/a
Concrete [2] Composite Wall System [3]
Values are based on the polymer web thickness, tdesign = 0.072 in [1] Royalloy B: E = 0.522 x 106 psi; Fu = 5800 psi; Acoring = 9.06 in2 [2] Normal weight concrete: E = 2.918 x 106 psi; f'c = 2900 psi [3] Composite member (foam mass density = 0.55 lb/ft2, foam area = 24.2 in2) [4] Stiffness of uncracked section [5] Stiffness of composite cracked section [6] teff is based on radius of gyration of uncracked
B-6

Technical Guide
Strength Properties of the RBS8i Wall System

The RBS8i wall system can be used as a structural member to support gravity loads and lateral loads. The strength properties of the wall system, shown in Tables B8 and B9, are calculated assuming that the compression stresses in the wall are resisted by the concrete and that the tension stresses in the wall are resisted by the polymer. Table B8: Factored Strength Properties, per foot
weight lbf/ft2 Polymer [1] Concrete [2] Composite Wall System [3] 3.8 66.9 71.3 A in2 5.02 63.10 94.48 Mr lbf.ft 2259 [4] 746.0 [5] 2259 [6] Vr Vertical lbf n/a n/a 2062 [7] Vr Horizontal lbf n/a n/a 4911 [8] t in 7.87 5.47 5.59 [9] EIx 106 lbf.in2 28.02 459.07 [10] 31.05 [11]
Lc (ft) 0.0 10.00 10.50 11.00 11.50 12.00 12.50 Pr (kips) 49.41 35.18 33.72 32.19 30.59 28.92 27.17 Lc (ft) 13.00 13.50 14.00 14.50 15.00 15.50 16.00 Pr (kips) 25.36 23.47 21.52 19.49 17.39 15.22 12.98 Lc (ft) 16.50 17.00 17.50 18.00 18.50 18.63 Pr (kips) 10.67 8.28 5.83 3.30 0.70 0.00
Values based on Laboratory Test Reports, Empirical Rules, CAN3-A23.3-M94 and ACI 318-95, [1] Royalloy B: E = 0.522 x 106 psi; Fu = 5800 psi; Acoring = 9.06 in2 [2] Normal weight concrete: E = 2.918 x 106 psi; f'c = 2900 psi [3] Composite member (foam mass density = 0.55 lb/ft2, foam area = 24.2 in2) [4] Mr = (0.8)(0.5)(Fu)(Sx)/12 where 0.8 is the temperature/load duration factor [5] [6] [7] Mr = (4.817)(0.6)( f ' c )(Sx)/12 Mr for the cracked section is governed by the polymer Vr = (2.408)(0.6)( f ' c )(Ac vertical)(0.8), where Ac vertical = 3.657 x 9.06 in2; 0.8 is the effective coring area factor [8] Vr = (2.408)(0.6)( f ' c )(Ac horizontal), where Ac horizontal = 63.10 in2
0.8 L c 2 t ) ) for e < , t = teff, Lc = unsupported height in inches 32 t 6
B-7

Technical Guide
Steel Lintels
Steel lintels are designed in accordance or the AISC Specification for Structural Steel Buildings or CSA-S16.1 (Canada). Steel conforms to ASTM A441, Grade 44 or CSA Standard G30.12M, Grade 300W. As shown in the following drawings, steel lintels are fabricated from structural steel angles and plates. For RBS4 wall system, TEE 106x9.5x74 and TEE 133x12.7x77 are used. For RBS6 and RBS8i wall systems, 2 ANGLES 89x64x6.4 and TEE 133x12.7x115 are used.
TEE 106 x 9.5 x 74
TEE 133 x 12.7 x 77
2 ANGLES 89 x 64 x 6.4
TEE 133 x 12.7 x 115
Table B10: Physical and Strength Properties of Steel Lintel

Mass
lb/ft
A
in
2
Ix
in
4
Sx
in
3
Mr
lbf.ft
Br
lbf
Vr
kipf
For RBS4 concrete-filled Walls TEE 106x9.5x74 TEE 133x12.7x77 2 ANGLES 89x64x6.4 TEE 133x12.7x115 8.0 2.34 3.84 1.45 4740 11.4 3.37 8.84 2.85 9290 For RBS6 and RBS8i concrete-filled Walls 9.8 14.8 2.87 4.38 3.60 10.84 1.51 3.17 4920 10340 5350 5670 6050 7370 34.6 58.7 41.1 58.7
B-8

Technical Guide
Thank you for reading the Technical Guide. We hope you found this guide informative while designing your project using The Royal Building System technology. As always, our main goal at Royal Building Systems (Cdn) Limited is to ensure that our valued customers are 100% satisfied with our service and with The Royal Building System technology. Should you have any questions or comments, we would like to hear from you. You may contact us at the following:
Mail:
1 Royal Gate Blvd. Woodbridge, Ontario Canada L4L 8Z7 (905) 264-0698 (905) 264-0699
Tel: Fax:
E-mail: info@rbsdirect.com Web: www.rbsdirect.com
Please visit the RBS DIRECT! section of our web site at www.rbsdirect.com for the latest version of this guide.

Technical Guide Ver2.0

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The Royal Building System

Royal Building Systems (Cdn) Limited www.rbsdirect.com

The Royal Building System

The Royal Building System

The Royal Building System

1. INTRODUCTION 1.1 The Royal Building System

Building SOLUTIONS for a Better World

The Royal Building System

About The Technical Guide

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The Royal Building System

Table 2.2: Materials Properties of Royalloy B

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2.2.1 Concrete Take-off

Table 2.4: Concrete Take-off (Imperial Units) RBS4

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3. CODE APPROVALS AND TECHNICAL PUBLICATIONS

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4. PRODUCT PERFORMANCE 4.1 Weatherability of Royalloy B

ASTM Test Method

Results + 2.15 + 1.87 + 0.98 - 0.34 + 0.01 + 0.92 97

Table 4.2: Weathering Properties of Royalloy B Outdoor

Method 6 months 1 year 6 months 1 year 6 months 1 year

a b Drop Dart Impact % Retention

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Fire Performance of Royalloy B

Fire Performance Self-ignition temperature

ASTM E84 ULC S102.2 ASTM E84 ULC S102.2 Footnote 6

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Fire Performance of Concrete-Filled RBS Walls

Table 4.4: Fire Resistance of RBS Walls

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Acoustic Performance of Concrete-Filled RBS Walls

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22.5 26.4 17.9 30.8 21.6

27.3 29.1 21.7 37.1 25.9

35.9 47.3 28.5 47.7 35.5

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Indoor Air Quality (IAQ)

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4.6.2 Mold and Mildew

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Figure 4.1: Termite Infestation Probability Map

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The Royal Building System

The Royal Building System

RBS Wall System as a Non-Structural Formwork

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RBS Wall System as a Structural Wall Assembly

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6.2.1 Concrete Strength

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6.2.2 Wall Openings and Concentrated Loads

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6.2.3 Wall Lintels

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APPENDIX A: Wall and Lintel Design Tables (Metric Units)

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Physical Properties of the RBS4 Wall System

Table A1: Physical Properties of RBS4 Wall System, per metre

Ix 10 mm 15.56 67.82 n/a

Sx 10 mm 311.2 1428.9 n/a

EIx 10 N.mm 56.0 1364.8 [4] 134.0 [5]