Thermally insulated structural sandwich panels for roofing applications

Flannery, Aiden Michael (2015) Thermally insulated structural sandwich panels for roofing applications. [USQ Project]


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The market for modular housing and infrastructure is growing remarkably quickly due to increasing costs of labour and the demand for energy efficient, long lasting buildings. The viability of using fibre composite sandwich panels for these applications formed the primary investigation of this research project. The flexural strength and thermal insulation were of main focus however fire resistance, cost effectiveness and lifespan were also investigated.

A literature review was conducted on the design methods, requirements and applications of fibre composite technology in the civil infrastructure industry. Based on these findings, the theoretical properties of the materials were than calculated and used to design a set of sample beams. The sample beams consisted of a rigid polyurethane core sandwiched between two fibreglass skins made from woven roving and chopped strand mat. The beams were tested in 3 point, 4 point, quarter-span and third-span bending. From the tests results, various material properties were calculated such as the core shear rigidity, core ultimate compressive stress, core ultimate shear stress and facing modulus. These mechanical properties along with the knowledge of failure modes gained throughout the testing period were used to redesign the sandwich panels. The final design was modelled in Creo Parametric with an FEA conducted using the Creo Simulation package.

Core crushing and skin delamination were the two most common failure modes observed during testing. The modulus of elasticity of the skins and shear rigidity of the core were calculated as 2797.5MPa and 2.4MPa respectively. The core ultimate compressive stress and shear stress were calculated as 0.3MPa and 0.34MPa respectively. The serviceability requirements governed the roofing panel design which resulted in a core thickness of 100mm and a thermal resistance (R) value of 5.75. The finite element analysis results confirmed the design satisfied the serviceability requirements with a variation of less than 10% when compared with the predicted values and physical testing data. A cost analysis revealed that the FRP sandwich panels were significantly more expensive than conventional roofing materials however key areas for design improvement and cost reductions have been identified.

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Item Type: USQ Project
Item Status: Live Archive
Additional Information: Bachelor of Engineering (Civil) project
Faculty/School / Institute/Centre: Historic - Faculty of Health, Engineering and Sciences - School of Civil Engineering and Surveying (1 Jul 2013 - 31 Dec 2021)
Supervisors: Banerjee, Sourish
Date Deposited: 06 Jun 2016 01:29
Last Modified: 06 Jun 2016 01:29
Uncontrolled Keywords: Fibre Composite, Sandwich panel, Roofing
Fields of Research (2008): 09 Engineering > 0905 Civil Engineering > 090599 Civil Engineering not elsewhere classified
Fields of Research (2020): 40 ENGINEERING > 4005 Civil engineering > 400599 Civil engineering not elsewhere classified

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