Project Life Insu-Shell

Reducing the Carbon Footprint in Concrete Construction

1 1 2 2
Silke Tomoscheit , Thomas Gries , Michael Horstmann , Josef Hegger
1
ITA, RWTH Aachen University, Aachen (Germany)
2
IMB, RWTH Aachen University, Aachen (Germany)

silke.tomoscheit@ita.rwth-aachen.de

Abstract
Within the Life INSU-SHELL project (Environmentally Friendly Facade Elements made of thermal insulated
Textile Reinforced Concrete) RWTH Aachen University together with industrial partners developed and im-
plemented an innovative and eco friendly modular system for sandwich facades. The thin-walled, light-weight
sandwich structure combines Textile Reinforced Concrete (TRC) and a PUR-rigid-foam-insulation. With the
use of TRC a large quantity of concrete material and therefore CO2-output can be avoided. The lower
amount of concrete used in the new elements results in a reduction of CO 2-output of about 70 % in compari-
son to a similar element of ferroconcrete. The lower weight saves energy and fuel. Moreover it reduces the
pollutant emission in transport and application. The employment of the innovative elements at the new
INNOTEX building (ITA: Institut fuer Textiltechnik of RWTH Aachen University) with a facade size of about
590 m saved large quantities of CO2-output in comparison to conventional building techniques.

Introduction
Concrete is the worlds mostly used building material. Advantages lie in its good mechanical properties as
well as the relatively low costs. Concrete is able to bear high pressure loads but has a low performance re-
sisting tensile forces. Building elements therefore need a reinforcement structure. Commonly used are rein-
forcements made of steel. To avoid corrosion of those ferroconcrete elements a minimal concrete cover of
3.5 cm is mandatory. This amount of concrete is not needed from a structural point of view. Textile rein-
forcement structures made of non corrosive materials like carbon and alkaline resistant glass allow for a
reduction of up to 85 % of the necessary concrete material. Concrete is the largest producer of CO2-emisions
in the building industry. By reducing the needed amount of material used in concrete construction up to 70 %
of CO2-emission can be avoided.

Intensive research was done within the last decade by the German research landscape in the field of Textile
Reinforced Concrete (TRC). In addition to the basic study of material properties and the structural behavior,
promising developments in production processes and advanced applications were made. Due to its material
characteristics TRC is an ideal building material for the manufacturing of filigree and light-weight building
envelopes.

Ventilated faades with extensions of up to 12.3 m and thicknesses of 20 35 mm are state of the art, but
require bracing substructures to limit the deformation of the thin layers of concrete to. Stiff, yet light and load
bearing cross-sections can be created with sandwich structures that allow large spans and additional sav-
ings in material usage and overall wall thickness. Sandwich panels for industrial and multi-storey buildings
are mainly made with layers of metal or reinforced concrete. Surface layers of textile reinforced concrete
combines the advantages of the aforementioned materials in terms of weight, sound/fire-proofing and offer
advantages in terms of corrosion resistance and design freedom. In comparison to conventional structural
concrete members the usable building area or the insulation thickness can be increased with the same cuba-
ture. Moreover the cost of transportation as well as connecting and fixing devices can be lowered.

Whereas the technology of sandwich building components made of TRC was already applied in laboratory
sized projects for research purposes of the Collaborative Research Center 532 (SFB 532) at RWTH Aachen
University, the implementation in a large scale building project with all the demands of an up-scaled devel-
opment and production was still nonexistent until recently. Within the EU co-funded project INSU-SHELL
(LIFE06 program) a collaboration between the Institut fuer Textiltechnik (ITA) and the Institute of Structural
Concrete (IMB) of RWTH Aachen University as well as the industrial partners Durapact GmbH (manufactur-
ing), Saint Gobain Technical Fabrics (consulting in textiles) and others was formed to develop, produce and
implement an insulated self-supporting sandwich faade made of TRC. The resulting faade system was
implemented on the new building of ITA as a part of the building envelope (Figure 1). This paper presents
selected parts of the performed investigations on a self-supporting sandwich faade made of TRC for a new
laboratory hall of the Institut fuer Textiltechnik, RWTH Aachen University. Furthermore the aesthetic and
structural physical properties of the technology were put into an ecological perspective by evaluating its car-
bon footprint, showing the superiority for a number of building applications by reducing energy usage and
CO2-emmisions. [1]

Figure 1 - INNOTEX building (Source: ITA)

Insu-Shell Sandwich Faade

Architectural demands

The sandwich faade is covering a total area of 590 m of the northern, western and southern faades of the
building and assembled of 216 single elements with 12 different geometries (Figure 2).

Figure 2 - Southern faade of INNOTEX building with TRC sandwich elements (Source: ITA and Carpus + Partner AG)

The geometries differ in panel height and width; but the general layout stays the same for all elements. The
panels are rectangularly formed with a horizontal alignment in the faade (Figure 3). The majority of the fa-
ade was assembled of two main types. For the northern and southern faade, the maximum element di-
mensions are 2,975 m x 0,975 m (standard element size P1) for the western side 3,425 m x 0,975 m. In the
areas of adjacent building parts and openings, special element types were required whose dimensions range
within the aforementioned panel sizes. The overall wall thickness is only 15 cm by easily meeting all re-
quirements regarding heat transition, sound and weather proofing.
 Figure 3 Horizontal alignment of the INSU-SHELL TRC faade: southern and western side (Source: ITA)

Geometry, materials and assembly of a panel

The maximum dimensions of the panels were L x H x T = 3.425 x 0.9750 x 0.18 m (Figure 4). The sandwich
section consists of a capable rigid polyurethane foam core and two thin textile reinforced GFRC (Glass Fibre
Reinforced Concrete)-facings with a principal thickness of 15 mm enlarged to 40 mm at the edging frames in
which the stainless steel connectors and the sealing gaskets are located.

Figure 4 - Standard Insu-Shell sandwich panel (Source: ITA, IMB)

The textile reinforcement was placed in the tensile zone of the concrete shells according to the structural require-
ments.
 Figure 5 - Placement of textile reinforcement (Source: IMB)

Two different warp-knit fabrics for reinforcing the concrete facings were designed by ITA (Figure 6). For the
15 mm thick facing an uncoated fabric (fabric 1) was chosen. It is a Tricot-weave with reinforcing Vetrotex
AR-glass rovings of 1200 tex. The frame part was additionally reinforced with an epoxy-coated fabric (fabric
2) with a higher load bearing capacity. It was also used in the highest faade elements on the western fa-
ade. The higher demand on the load bearing capacity was due to increasing wind loads in the top faade
row. The fabric is a Chain-weave with 5 mm distance between the rovings in weft direction and 8 mm dis-
tance between the rovings in warp direction. The fibre material of the Chain-weave is a Vetrotex AR-glass
roving with 2400 tex in warp- and weft direction. The area weight is 192 g/m in warp- and 143 g/m in weft-
direction. [2-17]

Figure 6 Tricot- (fabric 1, left) and Chain-weave (fabric 2, right) warp-knit fabric (Source: ITA)

The core material of the sandwich structure is rigid polyurethane (PU) foam core. It was chosen not only
because of its excellent heat insulating behaviour but also because of its ability to add to the load bearing
capacity of the sandwich elements. The heat insulation of the panels is designed according to the require-
ments of German regulations as well as to avoid condensation of water in the insulation. The difference of
surface and air temperature inside the building was designed to be smaller than 5 K. The transmission loss
of the panels was conservatively determined by the calculation of the heat transmission depending on the
proportions of areas of the used materials. For the mid-parts of the panels with an area of 2.24 m with a
polyurethane core type B2 50 and a heat transfer coefficient of 0.025 W/mK, a heat transfer coefficient of
UW < 0.18 W/mK was calculated. If the reduced insulation thickness of the applied mineral fibres with a
heat transfer coefficient of 0,035 W/mK at the panel edges as well as the connecting devices are taken into
account, a total heat transfer coefficient of UW < 0.3 W/mK was determined, which is far below the critical
value of current regulations. The principle layer design of the Insu-Shell faade technology is shown in Fig-
ure 7.
 Figure 7 - Photo of sample with different layers of sandwich panel (Source: ITA)

To ensure a durable sandwich action, 8 ductile pin connectors with a diameter of 4 mm have been designed
to relieve stresses perpendicular to the joints of core and facing induced by temperature, shrinkage and wind
suction. The bending and shear stiffness is of minor influence on the shear transfer between the facings. The
pin connectors supply a high axial stiffness. They are mainly subjected to normal forces. The at the same
time low bending and shear resistance of the connectors keep constraint forces in the connectors and TRC-
facings due to constricted temperature and shrinkage deformations of inner and outer concrete facing at a
low level. The dead load of the outer facing of about 160 kg is transferred by two diagonal steel ties which
are placed in the centroid of the front wythe in cooperation with a foam core (strut-and-tie). The tensile force
in the diagonal steel tie is directly transmitted to the upper horizontal support (Figure 8). The panel transfers
its dead load to 2 vertical supports while the wind loads are borne by 4 horizontal supports. All supports are
located at the inner TRC facing transferring the loads to the backing main load-bearing steel frame structure.

Figure 8 - Geometry and structural system of self-supporting sandwich panels (Source: IMB)

Mechanical Properties

A total of 10 prototype elements were tested in four-point bending tests under static and cyclic loading to
determine the load-bearing behaviour and capacity. The results of 3 representative bending tests are de-
picted in Figure 9 to describe the following observed phenomena. Due to the high load-bearing capacity of
the TRC facings all sandwich panels failed by shear rupture of the core. The load level at which the shear
failure occurred was significantly influenced by the quality of the adhesive bond between the notched PU-
foam-core and concrete facings. After shear failure the residual load-bearing capacity equalled 50 % of the
maximum load and was even then still larger than the design limit multiplied with the partial safety factor for
the polyurethane material. Due to the deliberately chosen core strength, a large reserve is remaining given
that the layers are connected by perfect joints. Panel 2 and 3 failed at a much lower load level due to some
large areas of poor bond quality leading to a concentrated and inhomogeneous shear flow in areas with good
bond. Furthermore a significant influence of the cyclic loads on the shear capacity of the foam did not be-
come evident from the performed tests. Tests on panels 2 and 3 with poor bond areas have shown that the
pin connectors and the surrounding concrete frame at the panel edges allow for secondary shear transfer
mechanisms like friction or principle positive locking. Thus, panels 2 and 3 also exceeded the demanded
design values in the ultimate limit state (ULS). The chopped fibres as well as textile fabrics effectively re-
duced cracking of the concrete facings. In the SLS no cracks were observed and even in the ULS only very
few cracks were visually noticed. [18-31]

Figure 9 - Results of prototype tests and influence of joint quality on shear capacity (Source: IMB)

Ecological Evaluation and Context to the 0-impact Approach

For evaluating the global warming potential for the period of 100 years (GWP 100) a life cycle analysis was
issued. The CO2-equilvalent and the consumption of primary energy were determined within the Insu-Shell
project using the method of Institute of Environmental Sciences (CML) of the University of Leiden. The cho-
sen performance features for comparing the Insu-Shell technology with other building techniques are the
load bearing capacity and the heat transition of 1 m faade. All eco-balance data is scaled to this functional
unit. The present approach only considers the early stages of the faades life cycle. This is partly due to the
fact that no data on later stages does exist as the technology and the first application are in use for only a
year. Considered are raw materials, production process and transportation to the construction site for a
standard sized element. In order to determine the ecological potential of the Insu-Shell technology the eco-
balance results were compared to a faade system consisting of a ferroconcrete load bearing structure, a
commonly used insulation and an outer shell made of cement asbestos with the same load bearing and heat
transition properties. Therefore, no significant differences are expected during the stage of utilization.

Results of the Life Cycle Analysis

The consumption of non regenerative primary energy for production and transport of a standard faade ele-
ment (P1) is 1006.21 MJ/m. The portions of non regenerative primary energy for the production process
inclusive the allocation of raw materials are approx. 98 %, whereas approx. 57 % are based on the input of
polyurethane and approx. 15 % on glass fibre material. Only 2 % are used for transportation. Additionally
minor amount of energy is credited by thermal recycling of production waste (0.14 %). The use of regenera-
tive primary energy of production and delivery add up to 19.51 MJ/m. The resulting overall energy consump-
tion is 1025.72 MJ per 1 m.

The global warming potential of the functional unit (1 m faade) for the considered life stages results in
69.34 kg CO2-equivalent/m. The production process inclusive the allocation of raw material is main origin
with a portion of approx. 98 % of the GWP. 38 % are caused by the input of polyurethane and approx. 28 %
by the input of glass fibres. The remaining 2 % are caused by transportation.

blast-furnace cement

0,20%
cement (unspecified)
1,10%
2,90% 0,10%
0,80% siliceous sand

9,20%
2,70% feldspath
5,30%
0,20%
1,30%
kaoline

27,80% 4,20% titanium dioxide, epoxy,

polycarboxylate
water

chrome steel

rigid PU-foam
30,00%
glass fibre

polyethylene terephthalate

37,90%
electrical energy
5,30%
transport

waste water

thermal recycling

Figure 10 Material contribution to global warming potential (GWP 100) (Source: TFI) [34]

When analyzing the ecological aspects of the stages production and delivery for textile-reinforced concrete
facade element with insulation layer (P1), it becomes clear, that primary energy consumption as well as
global warming potential are mainly defined through the use of polyurethane as insulation and glass fibre as
textile-reinforcement. The two components, which just cause about 9 % of weight of a P1 facade element,
are responsible for 73 % of consumption of non-renewable energy and 66 % of global warming potential.

The P1 faade, which is made of textile-reinforced concrete, just weighs about 17 % compared to the con-
ventional cement-asbestos-faade. During the processes of production and delivery, the Insu-Shell faade
offers the potential to reduce the primary energy consumption of non-renewable resources by 817.1 MJ/m2
and the global warming potential by 79.52 kg CO2-equivalent/m (Table 1).
Table 1 comparison of faade systems

Insu-Shell Cement asbestos

P1 faade
Weight [kg/m] 92,11 530,22
Primary energy consumption,
[MJ/m] 19,51 n/a
regenerative (lower heating value)
Primary energy consumption,
[MJ/m] 1006,22 1823,40
Non regenerative (lower heating value)
Global warming Potential
[kg CO2-equivalent/m] 69,34 148,86
(GWP 100)

The Insu-Shell elements global warming potential is just about 47 % of the conventional elements. Produc-
tion and delivery just needs about 54 % of non renewable energy, compared to the corresponding value for a
conventional element.

The evaluation of ecological aspects was performed according to the standardized procedure of the eco-
balance (see [27], [28]). In context of the Insu-Shell project, a critical examination by an independent author-
ity was not intended. [32-42]

Impact on environmental issues (CO2 0-impact approach)

The results shown in the ecological evaluation show the high potential of the TRC technology for the building
industry regarding the reduction of CO 2 emissions. The retrofitting of existing buildings as well the construc-
tion of new applications with material reductions up to at least 85 % while maintaining all structural advan-
tages of reinforced concrete proofs the superiority of this technology for a vast amount of building purposes.
The reduction of the global warming potential by more than 50 % compared to a conventional building tech-
nique while keeping the structural advantages and reducing wall thickness makes the building technology of
Insu-Shell capable of contribute to 0-CO2-solutions.
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