A BRIEF

INTRODUCTION
INTO THE
EVG-3D® PANEL CONSTRUCTION SYSTEM
(Changing Construction Methods Worldwide)
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Today we would like to introduce to you a new building and construction technology
based on so-called 3D panels.

A 3D panel consists of a three-dimensional welded wire space frame provided with a

polystyrene insulation core. Such panel is placed in position and wythes of concrete are
applied to both sides. This is shown conceptually on the first picture.

3D CROSS SECTION

COVER MESH

SHOTCRETE

DIAGONAL

EPS CORE

The Third UN Conference on Population had just been meeting in Cairo; an explosive
population growth is bringing about an abundance of world-wide problems in its wake.
In the 15 largest cities of the world alone, a demand for more than 100 million homes
with the necessary infrastructure will arise in the 15 years to come.
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The fast-growing population triggers the need for a new, cost-conscious building system
to satisfy the tremendous demand on low-cost housing in the world. The requirements
this building system has to fulfill are the following:

- Fast and easy erection with unskilled labourers

- Economical use of local materials

- Structurally stable construction

- Good thermal and sound insulation

- Use of prefabricated elements produced on an industrial scale (thus, low cost)

- Great variety of design features

- Minimum installation work on site (no cranes)

Traditional building methods, such as brick, concrete, steel and prefab comply only
partly with these requirements.

In the early 1960´s, the idea of using a three-dimensional panel with insulation material
sandwiched between two layers of welded wire fabric came up in the United States.

While the idea was sound, technology did not exist to economically and efficiently
mass-produce the panels, utilizing the most economical insulating and reinforcing
components.

Attempts have been made over the years to design a process to automate the
manufacture of a welded wire sandwich panel. EVG, an Austrian company known
worldwide for the manufacture of complete mesh welding plants and special equipment,
have designed and patented machinery specifically to mass-produce 3D panels.

The breakthrough of EVG’ s development is the use of Polystyrene sheets in module

size. The spacer wires are diagonally pierced through the plastic foam core and welded
to the two mesh layers. The spacer wires hold the core firmly.
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The panels produced by using EVG equipment are extremely rigid and ready for field
installation.

EVG’ s novel method combines the desired requirement listed above with a cost-
conscious production.

THE 3D MANUFACTURING PROCESS

The 3D Panels are produced on the fully automatic welding line 3D/48 which
assembles the 3 components: welded mesh, truss spacer wires, and insulation core
(polystyrene), and which welds them to a three-dimensional element - the 3D panel.
The plant produces 3D panels of highest dimensional accuracy.

The 3D panel receives its strength and rigidity from the diagonal spacer wires welded to
the welded wire fabric on each side. This produces truss behaviour which is very rigid
and provides adequate shear transfer for composite behaviour.
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The so-called standard 3D panel is shown on the following picture:

The cover mesh of the 3D panel meets the requirements of ASTM A 185 standards.
The diagonal truss wires, as well as the wire used in the manufacture of welded wire
fabric, are in conformity with ASTM A82. The insulation core is Type I expanded
polystyrene (EPS), complying with ASTM C578 and having a low density (approx. 15 ÷
20 kg/m³).

Different configurations of 3D panels are manufactured. Other thicknesses of insulation

(40 ÷100 mm; if required up to 150 mm) and concrete (40 ÷ 60 mm) as well as slightly
different wire gages are also available (Ø 2.0 ÷ 4.0 mm).

The number of diagonal wires per square meter can be determined on the basis of the
shear strength required. In general, the diagonal wire diameters range from 3.8 ÷
4.0 mm. The number of diagonal wires may range from 50 ÷ 200 per m². The quantity
of diagonals in 3D wall panels lies in the lower range, while the quantity of diagonals in
floor slab elements lies in the upper range.
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The standard widths of the 3D elements are 1.0 or 1.20 m, their lengths are variable,
and, as a rule, they are co-ordinated with the usual storey heights, thus approx. 2.8 ÷
3.0 m.

For the 3D construction method, the EPS insulation core fulfills several important
functions. On the one hand, it serves as shuttering for applying the concrete layers, on
the other hand it also acts as a displacement body in the sandwich construction method
of the 3D system. Moreover, it reduces the concrete requirement to a statically and
constructionally warrantable minimum. Last but not least, the EPS core also contributes
its share to the excellent heat insulation properties of the 3D constructions.

The 3D System offers extraordinary design flexibility. By varying the size of the wire
reinforcement and the thickness of the shotcrete, most structural requirements can be
met. The 3D system can be used in many building applications; residential, commercial,
industrial, and institutional; and it is designed to meet standard building code
requirements. The 3D system can be used in single-storey or multi-storey facilities,
curtain walls, sound barrier walls, load bearing walls, non-load bearing walls, retaining
walls and roofs.

What are the merits of EVG-3D® panels?

1. Straightforward automatic production of 3D panels on high-speed welding lines.

2. The pierced-through spacer wires hold the core firmly. No dislocation of the core
when guniting.

3. Use of cheap polystyrene sheets available everywhere. No cutting of hard-to-handle

strips. No expensive polyurethane foam.

4. Uniform shell thickness and proper embedding of the reinforcing mesh ensure
statically safe structures. Accurate dimensions of modules; tolerance in length:
± 5 mm. tolerance in width: ± 3 mm.

5. No spacer wire overhangs. The spacer wires are cut flush to avoid rust and injuries
when handling.

6. The three-dimensional wire structure results in maximum stiffness. The rigidity

ensures ease of erection and handling.

The 3D panel is basically conceived to be used as a total construction system, but it

can also be readily included in other construction systems as a component, i.e. in steel
frame or reinforced concrete constructions such as curtain walls, partition walls, and as
core in precast elements.

Although 3D panels were originally used predominantly for load-bearing and non-load-
bearing walls, they have also proved to be best suitable for different floor slab systems.
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The 3D panel cover mesh can also serve as bottom or top reinforcement of floor slabs.
This reinforcement is sufficient for spans of up to approx. 3 m; additional rebars can be
arranged for spans of up to approx. 5 m. Slabs with spans exceeding 5 m must be
provided with ribs which are reinforced with truss girders and additional rebars. This
system allows spans of up to approx. 7.0 m (see the next picture).

Prefabricated 3D panel slabs in conformity with «half-slab systems» are another

economical application of 3D panels, saving a considerable amount of working time.

Another advantage of this system is that during assembly the prefabricated slabs have
to be supported temporarily only once in midspan.

The 3D panel system is unique in providing a fast, economical, and easy construction
method which offers the builder a premier finished product. This system allows the
designer to efficiently use the same system in both load-bearing and non-load-bearing
applications.
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Earthquake Resistance

Forces acting horizontally on 3D buildings, such as earth quake forces, are transferred most
effectively by 3D shear walls. The respective “box-like” infilling with 3D panel walls in X- and Y-
direction of 3D buildings has to be provided. For dimensioning, 3D slabs and 3D walls can be
considered independently of each other. A frame-like design of 3D buildings with heavy
reinforcement in the joints is not necessary.

BOX-LIKE STRUCTURE

held by the slab immovable slab

(diaphragm effect)

LATERAL LOADS
cross wall
(shear wall)
anchored in the foundation
possibly boundary elements compression force

shear forces in the

tension force foundation anchors

In areas with a high earthquake risk it is recommended to use strengthened boundary elements
at the edge of a shear wall. These boundary elements are easy to carry out and they only
contain a small amount of reinforcement. In conjunction with 3D-panels they serve as tension
ties and form a structure with a very high resistance against earthquake forces. Unlike frame
structures boundary elements are flush with the walls and therefore, they will not affect the
architectural design. Especially in case of residential buildings a box-like 3D-structure is the
best solution to receive high strength and meet architectural requirements at the same time.
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Test Verification and Design of 3D Panels acc. to ACI (USA)

Numerous compressive strength tests carried out with wall structures manufactured
with the 3D construction method, as well as bending tests with floor slab panels, have
verified that the acknowledgement rules of reinforced concrete engineering also fully
apply to the 3D sandwich building technique. This means, by observing the reduced
statically effective cross section, all pertinent mandatory standards for reinforced
concrete engineering as well as all designing methods also apply to 3D sandwich
constructions.

Therefore, structural calculations of 3D constructions shall be made in accordance with

reinforced concrete strength design principles.

Tests have shown that 3D panels can be designed for compression and compression
with bending by using interaction curves constructed by standard strain compatibility.
An interaction curve for the standard 3D panel is shown in the next picture.
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Slenderness effects can be accounted for by using the moment magnification

procedure described in ACI 318-89, Section 10.11.5.

All 3D walls are considered as being «load-bearing walls». The proof of load-bearing
safety is furnished by means of interaction diagrams (tables) by using either the
approximate method - which is on the safe side - according to DIN 1045, or the design
according to ACI 318-89 (ICS Engineering Handbook). Load application eccentricities
of at least 3 cm are assumed for all walls (constructional imperfection).

DESIGN OF 3D COMPRESSION MEMBERS WITH ACI 318.89 (CHAPTER 10)

=============================================================

CHARACTERISTICS OF 3D-PANELS
-----------------------------------------------------
WIRE DIAMETER USED IN COVER MESH d = 3,0 mm
MESH SIZE a = 50 mm
DISTANCE EPS - COVER MESH (13; 16; 19) de = 16 mm
WIRE DIAMETER OF TRUSS WIRES dd = 3,8 mm
QUANTITY of TRUSS WIRES PER m² n = 58
WEIGHT OF COVER MESH (ONE LAYER) gg = 2,22 kg/m²
WEIGHT OF TRUSS WIRES PER m² g2 = 0,79 kg
WEIGHT OF 3D PANEL PER m² g3 = 7,23 kg
THICKNESS OF EPS e = 100 mm
THICKNESS OF CONCRETE PLASTER tens. t1 = 40 mm
THICKNESS OF CONCRETE PLASTER compr. t2 = 40 mm
STEEL AREA PER 1 m of COVER MESH As1 = 141 mm²/m
DISTANCE FROM COMPR. FIBER TO STEEL d1 = 161 mm
DISTANCE FROM COMPR. FIBER TO STEEL d2 = 20 mm

s= 90 mm

CONSIDERATION OF SLENDERNESS EFFECTS (ACI 318-89)

=================================================

Moment Magnification Method (Chapter 10.11.5)

---------------------------------------------------------------

SPECIFIED YIELD STRENGTH OF STEEL (N/mm²) fy = 500,0

SPECIFIED COMPR. STRENGTH OF CONCRTE (N/mm²) fc = 15,0
UNSUPPORTED LENGTH OF COMPR. MEMBER (m) lu = 2,8
RATIO OF MAX.AXIAL D.L. TO MAX.AXIAL L.L. Bd = 0,7
CRITICAL LOAD (FACTORED kN/m) 0.7* Pc = 766,0
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MOMENT FACTORED ACTUAL ECCENTRICITY

MAGNIFICATION AXIAL LOAD ALLOWED MOMENT
FACTOR Pu Mmax e
delta (kN/m) (kNm/M) (mm)
====================================================================
1,044 33 4,4 134
1,093 65 6,3 97
1,146 98 8,0 82
1,205 130 9,5 73
1,270 163 10,8 67
1,342 195 12,0 61
1,423 228 12,9 57
1,515 260 13,6 52
1,619 293 14,2 48
1,738 325 14,5 45
1,877 358 14,5 41
2,040 390 14,4 37
2,233 423 14,1 33
2,467 455 13,6 30
2,756 488 12,9 26
3,121 520 11,5 22

All 3D walls are also considered as being shear walls, and can therefore be used for
transferring horizontal loads, such as wind and earthquake loads. Owing to additional
reinforcements, all splices between walls and between walls and floor slabs are shear-
resistant and ensure a flexurally rigid, «modular» loadbearing effect of the whole
building.

Loadbearing Capacity of 3D-walls acc. to DIN

The following abridged print-out refers to walls with an eccentricity of 30 mm. The tables can be
used to design internal and external 3D-walls. The design method refers to DIN 1045. The
concrete with a specified compression strength of 14.5 N/mm² doesn't refer to DIN but it is
widely used. It corresponds to a concrete grade of B20.

e The figure shows the basic

load dimension of a 3D-wall. Eccentricity e
is assumed to 30 mm, which
corresponds to the requirements of
DIN (Germany) and ACI (USA).

concrete

t1 tEPS t2
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concrete- admissible axial load P [kN/m] for 3D walls

grade effective length of wall [m]
[N/mm²] 2.60 2.80 3.00 3.20 3.40 3.60 3.80 4.00 4.20 4.40 4.60 4.80 5.00 5.20
10.5 90 82 75 67 57 46 36 26 17 7 0 0 0 0
14.5 124 113 103 93 79 64 50 36 23 10 0 0 0 0
17.5 149 137 124 112 95 77 60 44 28 12 0 0 0 0
table 1 40 mm concrete + 50 mm EPS + 40 mm concrete

concrete- admissible axial load P [kN/m] for 3D walls

grade effective length of wall [m]
[N/mm²] 2.60 2.80 3.00 3.20 3.40 3.60 3.80 4.00 4.20 4.40 4.60 4.80 5.00 5.20
10.5 133 125 116 108 99 90 86 84 81 79 77 76 74 73
14.5 184 172 160 149 137 125 119 115 112 109 107 104 102 100
17.5 222 208 194 179 165 151 144 139 135 132 129 126 124 121
table 2 50 mm concrete + 50 mm EPS + 50 mm concrete

concrete- admissible axial load P [kN/m] for 3D walls

grade effective length of wall [m]
[N/mm²] 2.60 2.80 3.00 3.20 3.40 3.60 3.80 4.00 4.20 4.40 4.60 4.80 5.00 5.20
10.5 152 147 142 136 131 126 121 116 110 105 100 95 88 74
14.5 210 203 196 188 181 174 167 160 152 145 138 131 121 102
17.5 254 245 236 227 219 210 201 193 184 175 166 158 146 123
table 3 40 mm concrete + 100 mm EPS + 40 mm concrete

concrete- admissible axial load P [kN/m] for 3D walls

grade effective length of wall [m]
[N/mm²] 2.60 2.80 3.00 3.20 3.40 3.60 3.80 4.00 4.20 4.40 4.60 4.80 5.00 5.20
10.5 200 194 188 182 176 170 163 157 151 145 139 133 127 120
14.5 277 268 260 251 243 234 226 217 209 200 192 183 175 166
17.5 334 324 313 303 293 283 272 262 252 242 231 221 211 201
table 4 50 mm concrete + 100 mm EPS + 50 mm concrete

Loadbearing Capacity of 3D-slabs acc. to DIN

In general, flexural design of 3D-slabs can be carried out like design of reinforced concrete
slabs. the basic design model according to DIN 1045 is shown in the following sketch.

DIN-1045
straight fc
line
t2 d1 FC

d
dEPS parabolic z
curve
FT
steel (fy)
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On these conditions the maximum admissible moment under service load according to DIN can
be found in table 5. The dimensions for t2 and dEPS are indicated in mm and the moments in
kNm/m. Moments are calculated under service load including the safety factor according to DIN
(= 1.75) at a concrete grade of 17.5 N/mm² (= B25). For other concrete grades these values
have to be multiplied with fc/17.5 N/mm². The distance between the lower edge of the EPS and
the center of gravity of the reinforcement is assumed to be 20 mm.

concrete layer
EPS thickness [mm]
(compression)
[mm] 40 50 60 70 80 90 100
50 20.6 24.5 28.7 33.3 38.3 43.5 49.1
60 24.5 28.7 33.3 38.3 43.5 49.1 55.1
70 28.7 33.3 38.3 43.5 49.1 55.1 61.4
80 33.3 38.3 43.5 49.1 55.1 61.4 68.0
table 5 Maximum admissible moments M [kNm/m] fc=17.5 N/mm²

Shear Strength

Shear strength of 3D panels depends on the number of diagonals (100 or 200 diagonals per
sqm). For standard panels with 50 and 100 mm EPS the shear strength can be found in tables
6 and 7. If the shear strength is not sufficient additional shear reinforcement has to be used
(see next page).

EPS 100
concrete layer diagonals per m²
(compression) 200 100
50 mm 14.3 9.8
60 mm 14.3 10.3
70 mm 14.3 10.9
80 mm 14.3 10.9
table 6 Admissible shear forces for EPS 100 in [kN/m]

EPS 50
concrete layer diagonals per m²
(compression) 200 100
50 mm 13.8 11.0
60 mm 13.8 11.0
70 mm 13.8 11.0
80 mm 13.8 11.0
table 7 Admissible shear forces for EPS 50 in [kN/m]
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Additional shear reinforcement

ø 4.0 mm Galvanised shear trusses

All dimensions are in [mm]
Steel grade = 550 N/mm²
150

ø 4.6 mm ø 4.0 mm
150 150 150 150 150

The shear truss shown above is widely used with 3D-panels. The capacity under service load is
approx. 3 kN/piece. In most case the panels the shear trusses are placed between panels and
in a small slot in the centre of the panels, which results in a distance of 60 cm between the
shear trusses and an additional shear strength of approx. 5 kN/m. However, if required more
trusses can be placed or trusses with thicker wire can be used.

Thermal Insulation

Good thermal and sound insulation is essential for the quality of life in a home. The
thermal brake within each 3D panel is mainly modified expanded polystyrene. In its
standard thickness, a 60 mm core with 40 mm of concrete yields an R-11 rating. A
100 mm core of EPS covered by 50 mm of concrete gives you a highly efficient R-18
rating; using alternative insulating materials, even an R-33 can be attained. The effect
of local thermal bridges due to the truss wires of the 3D panel is dependent on the
number and the cross section of the truss wires. Truss wires made of stainlesss steel
provide better R-values.

Sound transmission

The sound insulation of a building is its property to screen the inside of the building
from exterior sounds, and to dampen interior sounds in their propagation from room to
room, respectively.

Due to its double-shell construction, the 3D panel configuration minimizes sound

transmission.

For a good sound insulation, walls consisting of a single shell must have a big mass
compared to their surface. This big mass can be reduced by using double shell walls as
in the 3D construction system.
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The following picture shows the weighted sound transmission value Rw of double-shell walls
with equal shell thickness in function of the max. m´ per surface of the total wall (set of curves
b) and the distance dL of the shells as a parameter.

With the 3D construction system it is thus possible to attain a specified sound transmission
value Rw by varying the shell thickness and the distance between the shells.

However, for a 3D panel the sound transmission values Rw shown will be reduced owing to the
truss wires and their quantity.

Fire Rating

The fire resistance of standard 3D panel constructions is mainly dependent on the thickness of
the concrete wythes and the quality of the aggregates used.

With 40 mm of concrete (carbonate aggregate) applied to both sides, each panel achieves a
fire rating of 90 minutes.

A 50 mm application offers a 120 minutes rating. Ratings can be increased by adding interior
and exterior treatments, coatings and finishes.
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Modified expanded polystyrene used in 3D panels is non-combustible. It will not contribute to

fire and simply melts when exposed to flame.

Now I would like to give you a brief general description of the recommended construction
procedure. However, as this system is so versatile, it would make no sense to attempt to
address all applications in this presentation.

3D construction panels are usually delivered on flatbed trucks. Their lightweight means they
can be unloaded either by hand or by forklift truck.

The light weight of the 3D elements used is another considerable advantage of the 3D
construction method. A standard element with the dimensions of 1.20 by 2.8 m has a weight of
just around 20 kg; therefore, it can be carried and handled by one person only. Costly site
equipment, such as cranes and hoisting implements are not required for setting up 3D
structures.

Foundations

Often plans will specify that a system of metal anchors be placed in the wall footing or slab to
secure the panel bases. Lengths of straight rebar extending vertically out of the concrete are
commonly used for this purpose. The panels are usually placed so that the rebar is set between
the mesh and the polystyrene. This arrangement provides easy wall alignment.
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When panels are to be placed on existing slabs, holes may be drilled on-line to house lengths
of rebar dowels. Other methods of securement to slabs may also be used. Metal channels or
sections of preformed U-shaped welded wire fabric can be fastened or anchored to the slab
with various fastening systems, including pneumatic power guns.

3D structures are around 40 % lighter in weight than standard concrete constructions, which
allows considerable savings in making foundations.

Handling of 3D Panels

Since panels weigh only 5.5 kg/m², one of the best features of using 3D panels is that they can
easily be set in place or stacked, using only a one or two-man crew.
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Erection of 3D Panels

The first two panels are placed on-line (forming a corner) and the adjacent panels are clamped
together, preferably using a pneumatic fastener tool.

After the first two panels are firmly attached, the panel tops can be brought on-line using
appropriate bracing. The type of bracing required will depend on several conditions, i.e. panel
height, wind conditions, etc.

The next picture shows one type of simple bracing commonly used. All bracing should be
located on the same side of the wall, opposite the side which will receive concrete first.
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Strips of 50 x 50 mm of cover mesh (the so-called splice mesh) are used to reinforce panel
seams. These strips are easily attached to the panels, also using the pneumatic fastening gun.
At corners, right-angle wire mesh is added inside and outside (called the corner mesh), and tied
to the panel mesh. U-shaped mesh is also available for certain applications at the top of walls,
or for wrapping free edges of 3D panels.

Openings

Openings for doors and windows can be cut out both before and after panel erection. In either
condition, several different methods can be used.

The recommended panel cutting method is to use a handled variable speed reciprocating saw
with a metal cutting blade with a minimum diameter of 100 mm.

If electrical power is not available on the job site, panels can be cut by using a pair of bolt
cutters to snip the mesh wires, followed with a hand saw to cut out the polystyrene.
19
 20

Once the opening is complete, a strip of suitable cover mesh is usually placed diagonally above
and below corners to prevent cracks. U-shaped mesh is also used in some cases to reinforce
window openings.

Utilities

Another great feature of this system is the way it accomodates utilities. Once panels are
secured in place, installation of utilities can begin. The gap between the polystyrene sheet and
the layer of wire mesh provides an excellent area for encasing both electrical conduit and water
pipe. Gas line and phone cable can also be run in this area.

The next picture is a good example of electric conduit run inside a panel. The cover mesh
provides a very convenient place to tie pipe and boxes in place.

Making Columns and Beams

Removal of some of the polystyrene panel may be necessary at times in order to strengthen a
certain area by filling it in solid with concrete. Truss pockets are also created in the same
fashion. Additional rebar may also be required in these cavities. Polystyrene removal can be
achieved quickly by a variety of means. One of the best methods to efficiently remove this
material is to use a high-pressure water spray.

Another method involves the use of a propane torch to melt the polystyrene. A heat gun may
also be substituted for some applications.
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Shotcreting

No attempt will be made here to cover all the features necessary to achieve good shotcreting
work. What will be covered is a general overview of the process with specific comments as it
relates to the 3D Panel System.

Covering the 3D panels with concrete can be achieved by a variety of methods. Concrete can
be applied manually or mechanically by using the wet (mortar pump) or dry (gun) process of
shotcreting. Concrete thickness varies, but usually it is twice the distance between the face of
the polystyrene and the cover mesh. In many cases, plans call for 35 mm of concrete on each
side of the panel. To ensure corrosion resistance, the steel mesh must be covered by at least
15 mm in normal environment. In aggressive environment, the concrete cover thickness has to
be increased.

It is not necessary to have all panel work completed before shotcreting begins. Often the
exterior walls will be shotcreted before utility installation is complete.
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Various systems may be employed to apply concrete to the panel surface. Each system has its
own unique method of screeding and finishing to achieve the desired surface. The type of
system to be used is determined by the structure to be built.
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After curing, a standard plaster finish coat and texture can be applied; admixtures for
workability may be used. This finish coat may be painted.
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Summary

By way of conclusion, I should like to summarize again the benefits of the 3D Construction
System.

1. The 3D System is a new, price-conscious and versatile construction method based on

quality-controlled 3D panels prefabricated on an industrial scale.

2. 3D panels are erected and assembled on site. Transport and handling is easy due to their
light weight.

3. 3D panels can be cut as required with conventional hand tools or by standard hand-held
electric saws.

4. After plumbing, and electrical or other utilities are installed, the entire structure is sprayed
with mortar.

5. The complete 3D panel structure is a composite, combining the strength of the steel, the
insulation of the polystyrene core and the durability of the concrete.